Since Construction Equipment Guide (CEG) last reported on Maine Department of Transportation's (MaineDOT) $52.85 million Ticonic Bridge Replacement Project in October 2024, Cianbro Corporation has advanced into Phase 2 of the initiative, which will link the communities of Winslow and Waterville, divided by the Kennebec River, with a targeted completion date of May 2027.
The new 566-ft.-long, five-lane bridge on Route 202 is being rebuilt on a new alignment as a two-span steel girder structure with a concrete bridge deck. A single concrete pier in the river and two abutments will support the new bridge. Streetscape improvements are designed to encourage walking and bicycling while enhancing the attractiveness and quality of life in the downtown area. These improvements include 5-ft. shoulders to accommodate bicycles, 6-ft. sidewalks for pedestrians and architectural lighting.
Designed by HNTB Corporation, the bridge features modern crashworthy bridge rails and corrosion-resistant construction materials intended to ensure a minimum lifespan of 100 years.
Prefabricated materials include steel girders up to 150 ft. long, weighing as much as 135,000 lbs., 96,000 lbs. and 51,000 lbs.
By October 2024, Cianbro crews had constructed the two-lane section on the north side of the bridge and poured the deck that fall.
"This was a milestone for us, just beating the cold weather," Tom Senior, Cianbro's project manager, told CEG. "We also placed the concrete sidewalks and continued completion of the Stage 1 superstructure."
Other completed elements at that time included bridge demolition, abutment construction and the start of temporary access installation.
The two-stage project replaces one-half of the bridge at a time.
In January 2025, Cianbro implemented its first full bridge closure to begin demolition work for Stage 2, which is scheduled to be finished this June.
"The first thing we did was the demolition of the old concrete arch, which began during the full closure between Stage 1 and Stage 2," said Senior. "The demolition started from the top, along with excavation of the soil inside the arch and removal of the remaining utilities."
J.E. Butler LLC was brought in to demolish the 600-ft.-long concrete arch bridge. To remove the soil, the subcontractor used large Komatsu excavators and dump trucks to transport debris.
"They were staged on top of the Stage 2 deck where traffic was closed," said Senior. "They removed the debris, loaded it into dump trucks and disposed of it."
Once excavation was under way, crews began tackling the arch walls using excavators equipped with pulverizing heads.
"Once they reached the arch floor, they started using a hydraulic hoe ram to hammer the arch as much as possible," said Senior. "The arch was known to be pretty unstable. The plan was to demolish it as much as possible from the top. At some point we knew the structure would fail and fall below — and that's what happened to each of the four spans."
Crews installed several protection systems below the structure and along the riverbed.
"We had a new pier that we constructed, and it was protected using traditional timber crane mats and rubber blasting mats to prevent damage to the new concrete bridge pier," Senior said. "We also had a new Shugart barge built from several sections of barge pieces in the upper impoundment area behind the dam to catch debris from the arch."
Extensive planning was required to safely bring down the arch, which was completed in January 2025.
"It was one of the pinnacles of the project," said Senior. "From the time of the bid, we recognized this operation as one of the major challenges because of the unknowns. The plan was to stay clear from a safety perspective while the arch fell."
Cianbro worked closely with J.E. Butler to plan the approach.
"It was great to work with J.E. Butler from day one and plan this operation," Senior said. "We held regular meetings with our most experienced Temporary Construction Structures Group and engineering design team members. Those discussions ensured the arch was brought down successfully."
To assist with the demolition, Cianbro supplied a Cat excavator and hydraulic cranes.
Debris was removed by excavators and trucks traveling along a temporary access road across the river.
"The riverbed is generally bedrock and quite frequently exposed due to water elevation controlled by the dam's operations," said Senior. "The temporary access road was built using riprap and concrete debris from the arch. We also had a temporary bridge across the main channel."
Both structures were constructed in accordance with environmental restrictions to protect Atlantic salmon and sturgeon.
"The bridge allowed us to bring equipment to the work site as did the temporary causeway, which we have operated since last September," said Senior. "It supports the demolition work we are conducting this season for the existing piers below."
Between April and August, the temporary causeway cannot be used due to water work restrictions. From Sept. 1 through March 31, crews can access the riverbed, which is essential for demolition operations.
"Since last September, we built the rest of the temporary causeway and installed a temporary bridge across the main channel," said Senior. "We then moved concrete debris and clean rock that we imported. J.E. Butler then began demolishing the existing piers."
The channel bridge built by Cianbro crews uses 79-ft.-long girders and is covered with timber mats. Approaches were built with concrete blocks and large riprap.
For roads on either side of the bridge, Cianbro and J.E. Butler used Cat, Hitachi, John Deere and Komatsu excavators, along with trucks. A GHC 130-ton hydraulic crawler crane and additional cranes lifted and placed the bridge beams.
Cianbro places a strong emphasis on safety. Senior highlighted the temporary access road as an example.
"It is the closest to the water that we are working," he said. "We have life rings and rescue boats available at all times, air horns in the event someone falls into the water, and a direct line of communication with the company that manages the flow of the river from the dam. We coordinate every morning regarding anticipated river flows."
If water levels are expected to rise, crews are notified in advance.
"We also have safety boats, conduct regular water rescue drills and have a protocol to call 911," Senior said.
Crew members are required to wear life vests when working close to the river. Construction teams working above the dam follow the same safety regulations.
"Working adjacent to a dam can be dangerous when the turbines are operating because the suction at the gates can be fatal," said Senior. "Every day we hold a morning meeting to discuss project activities and safety issues. There is constant communication."
The project generally operates on a day shift schedule, with crews working year-round.
"Working in winter is one of the challenges we face when using temperature-sensitive materials like concrete," Senior said. "We use forced hot air heating units and ground heaters to ensure the concrete is placed and cured according to specification and at the correct temperature."
Cianbro primarily uses a 4,000-psi concrete mix for bridge decks and other concrete elements. Suncoast Reinforcing is installing the rebar.
Cianbro has been a leader in Maine's construction industry for 76 years.
"Our relationship with MaineDOT is a long-standing one," said Senior. "We work together closely, and especially on this project the relationship between our team and theirs has been great. We collaborate regularly and communicate constantly. We share the goal of finishing the project safely without incidents and delivering a quality bridge."
Cianbro completed work on the north side of the bridge once the arch demolition was finished. This required moving two Mi-Jack Products rubber-tired gantry cranes to the deck site. Keeley Crane, a Maine-based subcontractor, used a 500-ton crane to lift and reposition the gantry cranes.
"We lifted the units, rotated them and set them down for the second phase," said Senior. "We rotated them to keep the operator's cab in the center, where access is best for exiting the gantry crane in an emergency. We have a long-standing relationship with Keeley Crane, and Cianbro Equipment & Logistics works closely with their team."
Stage 2 Progress
Stage 2 work is moving forward. All remaining steel on the Stage 2 side was placed last summer and fall. The second bridge deck closure placement on the downstream side also has been completed, and crews installed sidewalks and curbs. Railings are now in place.
"This winter the team has been advancing with demolition of the base and removal of the piers, and the temporary causeway is in the process of being removed by the end of March," said Senior. "All concrete work on the bridge is targeted to be completed in March. We have one deck placement remaining between the two phases — a three-foot-wide strip to bridge the gap between the two bridge decks."
This work requires close coordination between the field team and the engineering staff, led by Senior Design Engineer Joe Orlando.
"We coordinate with our survey department and quality control team to ensure everything is located correctly and that materials meet specifications," said Senior. "We also make sure the crews on the bridge have everything they need."
Following completion of the bridge structure, removing temporary access systems will be a key step.
"We have a SafeSpan Fast-Flange access system installed between each girder that allows the team to walk underneath the bridge while completing finishing work, inspecting the underside and removing forms and panels," said Senior. "Removing the access platform will be one of the final major steps in completing the bridge construction."
Cianbro's earthwork subcontractor, Ranger Construction, is expected to mobilize this spring to complete the remaining earthwork scope.
The project management team includes Senior Project Engineer Joe Marshall and superintendents Craig Holmquist and Clifford Albert.
"It's a very positive group," said Senior. "We all work together and focus on safety every day. Everyone is constantly looking for solutions and following the motto that ‘no one in this room is smarter than all of us.'"
The project also includes a younger workforce gaining experience from seasoned leadership.
"We have a young crew on this project guided by experienced leadership that is helping develop their carpentry, ironwork and equipment operation skills," Senior said. "They've been working very hard in the field, following our safety principles and working together to do things right. Sometimes winter weather makes it difficult, but they show up every day and give it their all."
At peak activity, approximately 50 Cianbro employees and 10 subcontractor team members were on site.
Demolition and excavation operations are expected to generate more than 8,000 cu. yds. of concrete debris.
Cianbro maintains an internal equipment team whose mechanics service equipment both in the shop and in the field.
"There were times when they were here daily to repair equipment," said Senior. "Our headquarters is about 25 miles from the job site. We're experiencing normal wear and tear, especially with excavators. Two mechanics also worked regularly on our Mi-Jack gantry cranes. We work with Mi-Jack to obtain parts for hydraulic and electrical issues and to develop solutions that minimize downtime."
Cianbro has a long history with the Ticonic Bridge.
"After more than 110 years of service, the Ticonic Bridge is being replaced due to structural deterioration," a March 2025 Cianbro web page stated. "The new bridge is designed to last a century. The original steel truss bridge was built in the 1800s, followed by a concrete deck arch bridge. Damage during the 1936 flood led to repairs and widening. In 1970, Cianbro participated in another widening project. More than 50 years later, MaineDOT determined full replacement was necessary."
Senior, who is witnessing the demolition of the existing bridge, said the previous work completed by Cianbro remained impressive.
"It was top-notch and in good condition for its age," he said. "The concrete was in great shape, but the steel was starting to wear and the bridge deck was showing signs of deterioration." CEG
(All photos courtesy of Cianbro Corporation.)
