Betsy Ross Interchange, Section BR2

Sector: Roads
Location: Philadelphia, Pennsylvania | Owner: PennDOT District 6-0 | Cost: $96.5 Million | Completion: 2024

Details: The Betsy Ross Interchange, Section BR2 is part of PennDOT’s multi-decade initiative to reconstruct and modernize I-95 through Philadelphia. The I-95 Revive, one of Pennsylvania’s most significant transportation investments, is projected to cost several billion dollars and continue through at least 2030. Section BR2, one of four phases of the Betsy Ross Interchange Project, sought to enhance safety and stability for the 160,000 vehicles that use the interchange daily through the complete reconstruction of this three-level interchange.

JBC Associates provided Construction Inspection services for the Section BR2 project, ensuring that the construction met high standards of quality, compliance and safety. Three lanes of traffic were maintained along I-95 at all times to maintain the economic vitality of the corridor. Collaboration with other team members was vital to address constructability issues as the project faced several significant challenges.

Site challenges required innovative solutions and meticulous planning to ensure the project could proceed smoothly. The project area crossed multiple passenger and freight rail lines, high-voltage transmission lines, a maintenance yard, and a neighboring creek. Careful coordination was required between the project team and Conrail, NJ Transit, Amtrak, and PECO to limit disruptions to power and minimize impact on trains crossing beneath the project site.

The BR2 project involves a curved ramp that passes over a Conrail freight rail line (Ramp B on I-95). The project team piloted the nation’s first steel curved tubular flange girder (TFG) span, designed to address complex site conditions including crossings over multiple rail lines and a creek and under electric transmission lines. This design required extensive collaboration with Lehigh University and PennDOT’s civil engineering team to develop a horizontally curved steel bridge that utilized a rectangular tube for its top flange.

When constructing the curved ramp, beams were delivered below the bridge using a 500-ton crane. Typically, two cranes are used for lifting curved girders, but the design allowed for the use of a single crane within a 550-foot radius to navigate site constraints. The innovative use of temporary support helped achieve two major goals: maintaining traffic on existing ramps to reduce detour durations and retaining existing infrastructure. This approach allowed for bridge demolition and construction activities to be performed in advance, ultimately reducing the detour duration by over a year.

The team constructed the tallest prefabricated T-Wall system in Pennsylvania to support the interchange. Maintaining traffic flow during construction was crucial. These systems allowed for the replacement of existing piers while keeping the bridge operational, minimizing disruptions to the local traffic network.

JBC Associates’ inspection services were vital in navigating the complexities of the project and ensuring it met high standards of quality and safety, contributing to its recognition as the ASHE Delaware Valley 2024 Project of the Year.