Puget Sound’s SR 520: One Project Begins as Another Ends
By Lori Tobias CEG CORRESPONDENT
In Puget Sound’s busiest transportation corridor, one major bridge project is ending as another, even bigger operation, gets underway.
Crews for Graham Construction & Engineering Inc. are putting the final touches on the $485 million Washington Department of Transportation (WSDOT) State Route 520 Montlake Project, designed to bolster transportation safety while bridging communities.
Meanwhile, designer-builder Skanska is beginning work on the $1.375 billion SR 520 Portage Bay and Roanoke Lid Project, the final piece of WSDOT’s SR 520 Bridge Replacement and HOV Program.
Under construction since 2019, the SR 520 Montlake Project replaced an old, seismically vulnerable four-lane approach bridge with a new three-lane structure dedicated to carrying eastbound traffic from Montlake to the floating bridge over Lake Washington, WSDOT Communications Manager Steve Peer said. The project also included a “com-
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ODOT Reports Progress On Van Buren Bridge; Eight Support Pillars in Place
The Oregon Department of Transportation (ODOT) announced on Oct. 23, 2024, that improvements to the Van Buren Bridge near Corvallis are proceeding, with crews recently completing the deep foundation shafts.
Of the eight concrete pillars that
will support the bridge on Oregon Route 34 over the Willamette River, four go about 70 ft. into the ground, but the other four are in the water and reach depths of more than 220- to 245-ft. to reach solid rock.
“That’s almost as tall as the Statue of Liberty,” according to the ODOT
release. “Altogether, these pillars use nearly 500,000 pounds of rebar and hundreds of cubic yards of concrete. Talk about a solid foundation.”
“There are always some complications in any construction project,” ODOT Public Information Officer
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Crews drive one of the casings that will provide underground support for the eastbound SR 520 bridge between the shores of Montlake and the floating bridge.
Crews remove a truss from the original Van Buren Bridge.
GSA Awards $33.2M Contract to Expand Washington Port
The U.S. General Services Administration (GSA) awarded a $33,203,280 contract to T1-RJS Joint Venture LLC for the design and construction of the expanded Pacific Highway Land Port of Entry in Blaine, Wash., as part of President Joe Biden’s Investing in America agenda.
The modernization project will bolster safety and security, while alleviating congestion and wait times for travelers and strengthening the local economy.
The award was made to a Pacific Northwest small business through the Small Business Administration’s 8(a) Business Development program. The North Bend, Ore.based LLC is a collaboration between Tribal One (T1), a tribally-owned company of the Coquille Indian Tribe, and woman-owned Native American-owned RJS Construction Inc.
The GSA said construction is expected to start by July 2025, with “substantial completion” slated for November 2026, The Northern Light reported.
“The Pacific Highway Land Port of Entry is another example of how the Biden-Harris administration is Investing in America to keep our country safe and build a more sustainable future while expanding opportunities for small businesses,” GSA Administrator Robin Carnahan said. “These investments are a triple win –– creating good jobs that boost
our economy and national security, saving taxpayer dollars through reduced energy costs, and building a stronger and more prosperous future for our communities.”
The Pacific Highway Land Port of Entry expansion project will modernize the port, altering its traffic configuration to meet the needs of the traveling public better. GSA plans to add four primary vehicle inspection lanes and one outbound inspection lane to the port and to further support the NEXUS program. Additionally, the port will have enhanced secondary inspection capabilities, including six enlarged bays for vehicle inspections. All inspection areas will include extended overhead canopies, new pavement and upgraded lighting.
The port expansion is funded with $25 million from the Bipartisan Infrastructure Law and $8 million from the Inflation Reduction Act (IRA). The IRA funds are being used to construct new lanes and canopies using low-embodied carbon concrete and steel.
The port, which connects State Highway 543 in Blaine with the Pacific Highway in Surrey, British Columbia, is a full-service 24-hour operation and one of the busiest United States/Canada ports in the western United States, The Northern Light reported.
The port, which was last expanded in 1999 has seen the amount of noncommercial vehicle traffic grow in recent
years, although it is predominantly used for commercial vehicles, The Northern Light reported.
The project’s material-related emissions will be reduced by an estimated 190 metric tons of carbon dioxide equivalent, compared to industry averages for the steel and concrete being installed. That is equivalent to the emissions a gaspowered car would generate by driving around the Earth 25 times. Material selections include over 4,900 cubic yards of low embodied concrete that meets GSA’s “Top 40%” global warming potential threshold.
“You cannot have a big-league economy with little-league infrastructure. Thanks to the Bipartisan Infrastructure Law and the Inflation Reduction Act, more people and goods will be able to safely and efficiently travel across the U.S.Canada border at the Pacific Highway Land Port of Entry in Blaine –– the largest and busiest port of entry in the Pacific Northwest,” U.S. Rep. Rick Larsen (WA-02), the lead Democrat on the Transportation & Infrastructure Committee, said. “A more modern port of entry will also reduce congestion and wait times for travelers, improve public safety, and further promote cross-border trade and tourism in the United States and Canada.”
(All photos courtesy of U.S. General Services Administration.)
Papé Machinery, ShoulderMaster Tout Strategic Partnership
Papé Machinery Construction & Forestry of Eugene, Ore., a leading equipment provider with a strong presence across the West Coast, and ShoulderMaster, an innovator in road construction attachments, announced on Oct. 28, 2024, a strategic partnership aimed at transforming the road construction industry.
This collaboration combines Papé Machinery’s extensive network and commitment to customer service with ShoulderMaster’s cutting-edge technology, promising to enhance efficiency, safety and sustainability in road construction projects.
“At Papé Machinery, we are dedicated to providing customers with the best tools and resources, and our partnership with ShoulderMaster aligns with that commitment," said Scott Benham, the company’s vice president of machine sales. “This partnership allows us to offer our customers an even wider range of solutions, further solidifying our position as a trusted partner in the industry.”
both operators and road users while minimizing disruptions.
ShoulderMaster has earned a reputation for its sustainable approach to road construction, reducing reliance on raw materials, optimizing operator efficiency and minimizing fuel consumption. Its innovative attachments are designed to improve safety for
“We are thrilled to be partnering with Papé Machinery. This partnership expands ShoulderMaster’s reach and reinforces their commitment to innovation and customer success,” said ShoulderMaster Managing Director Craig Pinson. “We are confident that this collaboration will significantly benefit contractors by providing them with access to the most advanced and sustainable road construction solutions available.”
This partnership marks a significant step in ShoulderMaster’s expansion within the
U.S. market, demonstrating its commitment to collaborating with industry leaders to drive innovation and deliver exceptional value to customers.
Papé dates to 1938 when its founder, E.C. Papé, acquired his first capital equipment dealership in Oregon’s Willamette Valley.
The current entrance to the Pacific Highway Land Port of Entry in Blaine, Wash. Another view of the port entrance.
THE DOER’S DREAM
Loved for the features. Trusted for the performance.
Hyundai wheel loaders have the power and performance, not to mention top-notch interiors, accurate onboard weighing system, industry proven drivetrain durability, clear sightlines, and handy tech that make life on the jobsite easier. So you can do more without feeling it. No wonder so many first-time Hyundai users become longtime fans.
SR 520 Portage Bay and Roanoke Lid Project Under Way
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munity-connecting lid” in Montlake and a bicycle-pedestrian “land bridge” over SR 520, east of the Montlake lid.
The project is an example of how WSDOT is taking a new approach to transportation, Peer said.
“We’re building highways, yes, but not like our grandparents, who built roads just for cars,” he said. “The biggest thing that we did and are about to unveil is a 3-acre lid over SR 520 called the Montlake Lid. The lid is about 60 percent green space and is a transit hub.”
Peer described the lid as essentially a park over a highway. WSDOT previously built three of the lids in the BellevueRedmond areas.
“It’s very innovative,” Peer said. “The lids kind of connect communities that were torn apart when SR 520 came through in the early 1960s and dissected Montlake. It’s really going to be a centerpiece for the neighborhood.”
The other piece of the Montlake project is the bicycle and pedestrian bridge over SR 520 designed to take some of the bikes and pedestrians off Montlake Boulevard, a well-trav-
eled north/south connection.
“That one is 72 feet wide and, of those 72 feet, 14 are for bikes and pedestrians,” Peer said. “On either side of the bikes and pedestrians, it’s all greenery and it’s elevated. So, when you’re riding a bike over SR 520 and you look to the left and right, unless you’re really tall, you won’t necessarily even see SR 520 below.”
With the SR 520 Montlake Project ready for the final walk-through, attention turns to the SR 520 Portage Bay Bridge and Roanoke Lid Project.
The project was awarded to Skanska in early 2024. It will replace the aging Portage Bay Bridge with a seismically resilient structure that includes improved bus/carpool travel and an extension of the SR 520 Trail, Peer said. The project includes a landscaped lid between Seattle’s Roanoke Park and North Capitol Hill neighborhoods.
“Barges are coming in as we speak to begin building the work trestle that will be the workhorse for the lanes,” Peer said. “The bridge is over water, not floating, but with actual
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Contractor crews in 2021 remove some of the final columns of the old SR 520 west approach bridge in Lake Washington.
Aerial before and after views of State Route 520 approaching the Montlake neighborhood in Seattle. Since 2019 crews have built a new eastbound bridge that connects to the floating bridge in Lake Washington.
The final stages of construction on the SR 520 Montlake lid and interchange are ongoing.
Crews set up a protective tent to cover the fresh concrete on the 520 walking and cycling trail.
Crews work in 2021 with a paving machine just east of Montlake Boulevard to place the first concrete deck section for a future freeway lid over SR 520.
Waratah Forestry Equipment Launches New HX Line
Waratah Forestry Equipment has launched an all-new HX line with its 624HX and 626HX harvester heads and purposebuilt LPX loader-processor head. Building on generations of Waratah HTH attachments, the new extra-large harvester and loader-processor heads have been redesigned for extreme applications.
“All part of our new HX [harvester extreme] line, the 624HX, 626HX and new loader-processor LPX are more durable and higher performing than previous models,” said Brent Fisher, product marketing manager of Waratah.
“We understand the challenges loggers face to produce more wood each day, and we listen and evolve our products to meet their needs. These heads are designed to deliver tremendous performance so our customers can confidently take on extreme applications and experience measurable results.”
Impressive Performance
Weighing in at 8,796 lb., the redesigned 624HX harvester head delivers impressive log picking, feeding and handling with unmatched uptime, according to the manufacturer. This efficient 600-Series head provides the durability, reliability and speed loggers need to maximize every minute of work.
The new 626HX harvester head redefines Waratah’s legendary Bigwood head with even more performance. Weighing in at 10,141 lb., this 600-Series head takes feeding and delimbing to the next level. Its large 37.4 in. sawing capacity helps boost productivity day in and day out.
In addition, the 624HX and the 626HX boast a slew of beneficial HX-line features. The main frame and tilt frame provide improved durability and are optimized for weight and strength. The heads feature stronger clamping force to provide better log grip at the deck and holding power.
With HD-swept profile delimb arms, the 624HX and 626HX feature improved log picking due to larger delimb openings. Feeding is improved by new diameter sensor technology, while arm design helps log transport. Larger saw capacities, improved saw control plus larger saw motors contribute more efficiency and power to the cut.
A new main control valve provides better flow, cooler operation and higher working pressures. It also allows an improved layout and better feed-motor synchronization. The valve cover is stronger and sleeker with tough hinges and a quick latching system.
Features like the new auto-tension top saw, an improved measuring arm design, a hinged and removeable oil tank and feed arm hose bulkheads contribute to accessible and simplified servicing. Easy-access grease points and grease banks enable the greasing
and
of the entire head in less than 15 minutes. Loggers can tailor the heads to their operation with options like higher-torque feed motors, a variety of feed wheels, dual rotate motors, LED and SED color-marking systems and more.
Purpose-Built, Balanced Productivity With LPX
The all-new LPX is a purpose-built loader-processor head that includes many of the new HX line features. With a weight of 8,973 lb., this durable head is built to work in tight spaces, with balanced grapple and processing capabilities to improve daily productivity.
The LPX makes no compromises on log processing quality. Its wide grapple opening and two delimb/grapple arms provide optimum delimbing, deck processing and log handling to keep timber moving.
The new auto-tension top saw on the LPX has even more capacity, allowing for sawing large-diameter or multiple logs, and greater rotate torque and power improve log placement capability. Additionally, the high, wide saw box improves log picking over the side of a landing. The LPX’s sleek, short-tilt frame tilts for feeding and decking logs on slopes and reduces swinging for smoother operation in and out of the log deck. It also provides better servicing and valve accessi-
bility than previous LP models. The LPX, 624HX and 626HX heads all utilize the TimberRite H-16 control system for optimum head performance, productivity and measuring accuracy.
All Waratah heads come with easily accessible support for dealers and products, and genuine Waratah parts with an industryleading warranty.
These heads are now available to customers in the United States, Canada, Europe, Australia, New Zealand, Asia Pacific, Brazil and Latin America.
For more information, visit Waratah.com.
(All photos courtesy of Waratah.)
The Waratah 624HX harvester head delivers impressive log picking, feeding and handling.
The Waratah 626HX harvester head takes feeding and delimbing to the next level.
The purpose-built Waratah LPX loader processor is built to work in tight spaces, with balanced grapple
processing capabilities to improve daily productivity.
FALCON WINCH ASSIST
FALCON GRAPPLE CLAW
Van Buren Bridge Project Replaces Structure From 1913
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Mindy McCartt told The Daily Barometer. “Our surprises came underwater.”
Hamilton Construction Co. of Coburg, Ore., the contractor for the $85.1 million project, had to make regular adjustments during drilling before reaching rock layers, according to The Daily Barometer.
McCartt explained that they had to constantly make adjustments as they drilled through layers of earth to hit solid rock.
ODOT noted that the original bridge built in 1913 used no steel in its concrete supports. The new bridge supports will be packed with steel and feature more modern engineering, allowing it to handle far more weight.
“Plus, it’s designed to move during an earthquake without getting damaged,” the release said. “Its special expansion joints let the bridge shift over a foot lengthwise and up to 10 inches side-to-side.”
The bridge is being replaced because it was considered seismically vulnerable, was a bottleneck to traffic and freight, was weight-restricted and had low clearance.
The replacement will be earthquake-ready, have two eastbound travel lanes, a bike lane and a protected bicycle and pedestrian path. Improvements also are scheduled for the Van Buren Avenue and NW First Street intersection. Project development occurred between 2019-2022 and construction began in May 2023.
Steel girders that will form the backbone of the bridge are the next step in the construction process.
ODOT expects construction will be sufficiently completed by the late spring/early summer of 2025 to allow traffic to be shifted onto the bridge, with the two temporary bridges then removed. Site cleanup and restoration will continue into 2026.
(All photos courtesy of the Oregon Department of Transportation.)
An overhead view of ongoing construction on the Van Buren Bridge.
Workers lower a rebar cage into one of the deep, inwater foundation pillars for the new Van Buren Bridge.
The under construction Van Buren Bridge and the temporary bridges.
Demolition crews remove part of the original Van Buren Bridge.
Port of Kalama Receives $26.3M Grant to Help Port Speed Grain to Market
Clark Construction Breaks Ground On Forensic Hospital
Clark Construction Group joined Washington Gov. Jay Inslee and Washington State Secretary of the Department of Social and Health Services (DSHS) Jilma Meneses on Oct. 17, 2024, at a groundbreaking ceremony for the $947 million Western State Hospital’s new forensic facility.
The Port of Kalama, Wash., will receive a $266.32 million federal grant to pay to replace tracks and allow the port — already one of the largest grain exporters on the West Coast — to load grain cargo faster. U.S. Sen Maria Cantwell of Washington announced in a news release.
“We need to be thinking about the export opportunities in the United States,” said Cantwell, chair of the Senate Committee on Commerce, Science, and Transportation during an Oct. 26. 2024, tour of the port.
“We know how many jobs are related to trade activity, but not everybody in the country does, so we have to communicate to them,” she said. “You guys are representing all the way back to the Midwest, right? This isn’t just about us, even though we’re a big wheat-producing state. This is about the whole country getting product all the way to Asia. This is a huge, huge economic opportunity, and we have to build capacity in order to take advantage of it.”
The port sits along the Columbia River near Interstate 5 in southwest Washington, about 30 miles northwest of Portland, Ore.
The project will replace rail tracks at the Port of Kalama’s Tacoma Export Marketing Co. (TEMCO) Terminal. The replacement tracks will support storage of two loaded and two empty trains simultaneously at the port — expected to increase the loading efficiency of grain from rail to ship by up to 30 percent. In addition to the federal funds, the Port of Kalama will contribute a 20 percent match.
The Port of Kalama plays a key role in transporting cargo in and out of the Pacific Northwest and from as far away as South Dakota. Fifty million tons of cargo travel up and down the Columbia River, including more than half of the United States’ domestically grown wheat. The TEMCO Terminal directly employs 140 people who load up to 2 million bushels of grain every day. This rail project also will create an additional 40 construction jobs.
Progressive Railroading reported that the project will add 25,000 linear ft. of track for the staging of both loaded and unloaded trains. Additional work will include right-of-way acquisition; engineering; mitigation; track removal; realignment; and the expansion of nearby recreational amenities,
The port leases the grain facility to TEMCO, according to Progressive Railroading. TEMCO then uses the terminal to export feed grains, soybeans, oil, seeds and wheat to Asian and Pacific markets. The terminal has one berth with a water depth of 40-45 ft. It can load 120,000 bushels of grains per hour and store 6.5 million bushels.
TEMCO’s average volumes have grown drastically in recent years, according to Progressive Railroading There were 7.6 million metric tons of exports in 2013. By 2021, the total was 15.3 million metric tons.
The Port of Kalama grant was one of nine major investments in Washington state’s rail system infrastructure announced by the U.S. Department of Transportation in October, totaling $115,577,598. The improvements will boost railroad capacity all across the state, helping move freight and agricultural products quickly and more safely between our communities and international markets.
The grants come from the Federal Railroad Administration's (FRA) Consolidated Rail Infrastructure and Safety Improvements (CRISI) Program, which funds projects that improve the safety, efficiency and reliability of intercity passenger and freight rail.
Cantwell secured $5 billion over five years for the CRISI program in her Surface Transportation Investment Act, which was included in the 2021 Bipartisan Infrastructure Law, tripling annual funding for the program.
(All photos courtesy of office of U.S. Sen. Maria Cantwell.)
Clark is building a 467,000-sq.-ft., 350-bed forensic behavioral health hospital for skilled psychiatric treatment in a secure, therapeutic setting. The scope includes a 53,000sq.-ft. administrative building.
“We are honored to be a part of this important project and work with both DSHS and the Department of Enterprise Services to bring this new facility to fruition,” Clark Senior Vice President Eric Olson said. “This project has the capability to transform the access to mental health in this region, and we can't wait to start the construction phase.”
Work began in the spring of 2024, with the demolition of 11 existing outdated structures across 35 acres to prepare the site for vertical construction.
Clark is the general contractor for this project, with HOK serving as the architects. KPFF is the structural and civil engineer, and Affiliated Engineers, Inc. (AEI) is the mechanical, electrical and plumbing engineer.
Loren Supp, the senior project designer for HOK, explained the project’s approach in a company news release.
“The design supports holistic healing and rehabilitation of forensic behavioral health patients, challenging more institutional models,” he said. “The new hospital highlights the need for progressive services, programs and designs to optimize long-term outcomes for vulnerable populations.”
Project completion is slated for 2028.
(L-R): Port Commissioners Randy Sweet and Patrick Harbison and U.S. Sen. Maria Cantwell view railroad tracks leading to the Port of Kalama.
(L-R): Port Commissioner Patrick Harbison, U.S. Sen. Maria Cantwell and Port Commissioner Randy Sweet tour the Port of Kalama on Oct. 26, 2024.
columns that go into the water. So, we have the existing SR 520 with 75,000 vehicles going east/west on it every day, and we have to keep traffic moving. So, we’re actually going to build the bridge in stages.
“First, we’ll make a work trestle, and that trestle will help us build a bridge to the north of the current lanes. We’ll build those lanes, and then we’ll shift traffic onto those lanes, and then remove the existing highway lanes and build another bridge — twin bridges — across Portage Bay. Then, we will actually add another lid to that area.”
The biggest challenge on the Montlake Project was building in a highly urban environment, sort of like hosting a dinner party amid a kitchen remodel, Peer said. The Portage Bay project comes with challenges, one of which is to keep traffic moving, but also appeasing neighbors.
“Portage Bay can echo sound, and I think the noise for the neighbors is going to be difficult,” he said. “We’re warning neighbors it’s going to be loud. The other big challenge for that project is the amount of years it’s going to take, which is seven. People get construction fatigue. It’s a long project.”
The $5.59 billion SR 520 Bridge and HOV Program has been in the works since 2011, with the final Portage Bay Project set for completion in 2032. The program rebuilds one of the Puget Sound region’s busiest highway corridors and is designed to enhance
travel safety and mobility with modern, structurally stronger bridges, as well as substantial transit and roadway improvements along the urban corridor, according to the WSDOT website.
Built in stages, the improvements extend from Interstate 405 in Bellevue to Interstate 5 in Seattle.
Here, according to WSDOT, is what the public will see when the SR 520 corridor’s reconstruction is complete:
• New, structurally resilient bridges over Lake Washington, Union Bay and Portage Bay.
• A dedicated bus/carpool lane in each direction between Seattle and Bellevue.
• Three transit stations for local and regional bus routes.
• Five landscaped freeway lids over SR 520 — three on the Eastside, two in Seattle.
• A 14-ft.-wide walking and cycling trail between Seattle and Bellevue, a bicycle-pedestrian “land bridge” over SR 520 in Seattle’s Montlake neighborhood and a 30-ft.-wide bicycle and pedestrian crossing over I-5.
• A reversible transit/HOV lane along I-5’s express lanes between the SR 520 and Mercer Street interchanges, with reversible ramps at both interchanges.
• A system to capture and filter out stormwater pollutants from SR 520 highway runoff. CEG
(All photos courtesy of the Washington State Department of Transportation.)
Longstanding SR 520 Projects Set for 2032 Completion
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