The I-895 connector is part of a $354M transportation project that connected I-95 and I-295 with an 8.8 mile tollroad and a bridge across the James River. Located 10 miles south of downtown Richmond, Virginia, the project incorporated many different segmental construction methods. VSL held an $8.5M subcontract with joint venture partners Recchi America and McLean Contracting, contracted to construct the interchange superstructure for design-build joint venture partners Fluor Daniel and Morrison Knudsen.

The interchange required unique design elements in that the vertical clearance for cargo vessels entering the port of Richmond and passing under the bridge’s main span could be no less than 44 m. The 205 m main span was constructed using cast-in-place (CIP) segmental construction. For the CIP section, VSL supplied six, 3-horse form traveler headings and was  responsible for the supply and installation of the post-tensioning components in the crossing. The river crossing consists of five cantilevers in two bridges, eastbound and westbound. There are a total of 190 CIP segments, both 4 and 5 m lengths. The 12.5 m deep section at the pier tables required the form travelers to support the 350-ton concrete load. P-T bars were used at the pier tables and top deck closures.

The precast segmental approaches (balanced cantilever) were erected on the river’s west side using an overhead launching gantry while the east approach spans used cranes. The unique gantry design allowed for Recchi to erect two parallel bridges concurrently on the west approach. The bridges were then joined with a conventionally reinforced longitudinal closure pour. Three of the ramp structures leading to the interchange incorporated span-by-span erection using an underslung truss. VSL supplied all post-tensioning components and installed duct and anchorage assemblies to the 1,700 precast segments in the casting yard, located five miles from the site. More than 2,600 tons of strand was used on the project. VSL crews performed the grouting operations for the entire project.