BNSF 53.5 Rock Creek Bridge Replacement
Project Details
Owner: BNSF Railway
Location: Stevenson, WA | December 2021 – August 2023
Advanced American Construction (AAC) managed the complex replacement of BNSF Bridge 53.5, located over Rock Creek near Stevenson, WA. The project was part of BNSF Railway’s broader initiative to modernize aging pin-connected truss bridges across its network. Originally constructed in the early 1900s, the existing bridge required full replacement to increase load capacity and improve long-term structural safety. Construction was performed under tight environmental regulations, limited site access, and ongoing train traffic on BNSF’s main line into the Pacific Northwest.
Midway through construction, AAC identified a critically deteriorating in-service abutment, which required an immediate shift in project scope. Rather than proceeding with full bridge replacement, the team executed an emergency “mini-changeout” during a narrow 16-hour window. This effort involved demolishing and replacing half of the existing approach spans with precast concrete girders, while also stabilizing the structure to keep the rail line safely operational. Following a six-month pause at BNSF’s request, AAC resumed work in early 2023 to complete the final span replacement.
Final installation required heavy lifting in tight quarters. AAC mobilized two Manitowoc 4100 Ringer cranes, operating within a confined 50’x50’ footprint, adjacent to Rock Creek on temporary crane pads. The team executed a 400,000-pound dual-crane truss lift during a 31-hour scheduled rail shutdown, precisely coordinated with BNSF, Amtrak, and other stakeholders. To expedite demolition, and overcome clearance issues, AAC and partners notched an active pier beneath a live rail line and shifted the new span five feet south to allow a full 360-degree crane swing. AAC collaborated closely with OXBO Heavy Transport to slide the new 208-foot bridge into position using a hydraulic skid system.
Throughout the project, crews navigated severe wind conditions in the Columbia River Gorge, fluctuating water levels, challenging geotechnical conditions, and narrow construction windows—all while maintaining a perfect safety record. AAC’s ability to adapt, innovate, and collaborate made this bridge replacement a standout example of partnering excellence under pressure.
Project Highlights
- Emergency stabilization of failing bridge abutment
- 16-hour “mini-changeout” and 31-hour full span changeout
- Existing concrete abutments cut under live rail traffic to expedite removal during bridge changeout window
- 400,000-lb truss lifted and set onto floating barge
- 3 Million-hydraulic skid system
- High winds and unpredictable weather in Columbia River Gorge
- Modified crane matting and swing clearance solutions
- Continuous collaboration with BNSF, HNTB, OXBO, and permitting agencies
- Incident and injury free execution
Project Awards
