Project Details

Client: Veritas Steel
Location: McCracken/Livingston County, Kentucky
Capex: $95 Million
Project duration: 2010-2013
Owner: The Kentucky Transportation Cabinet
Design firm: URS Coporation
Architect: N/A
Engineer: URS Coporation/Stantec
Contractor: Kay & Kay Construction Co. JV Haydon Bridge Co.

Scope of Work

  • Modeling and shop detailing of approximately 7,500 tons of structural steel including top and bottom chord members, diagonal members, floor system, bracing, and complex knuckle assemblies

Project Stats

  • State-of-the-art truss superstructure, which is not cluttered with vertical members and sway bracing used in conventional truss designs
  • Bridge features 71-ft-wide deck with four driving lanes, a 4-ft shoulder and a concomitant 5-ft shoulder that will be designated as a bicycle lane
  • Serves over 8,000 vehicles per day
  • 900-ft main span (Warren Truss) is one of the longest built for a constant depth truss and eighth-longest continuous truss span in the world
  • 60-ft constant truss depth
  • It is an unusually lightweight steel truss; steel weight of truss skeleton is less than 100 lb per square foot deck area


Highlights & Challenges

  • Use of staggered bolt patterns helped reduce gusset plate sizes. This helped lower costs by reducing the size of the gusset plates, number of bolts and holes and degree of labor required for installation.
  • Created specific knuckle assembly models for fabrication sequencing and phasing to allow the fabricator to review accessibility prior to assembling the complex knuckle assemblies.


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