Skanska USA Civil has officially begun work on the $220 million Phase Three painting and structural rehabilitation of the Commodore Barry Bridge, a critical infrastructure link spanning the Delaware River between Chester, Pennsylvania, and Bridgeport, New Jersey. Awarded by the Delaware River Port Authority (DRPA) in January 2025, this extensive project aims to extend the service life of the fourth-longest cantilever bridge in the world, ensuring the safety and reliability of a structure that supports nearly 15 million vehicles annually.
The rehabilitation focuses on comprehensive structural steel repairs, protective coating applications, and modernization of electrical systems, with completion targeted for the first quarter of 2028. This major undertaking underscores the DRPA’s commitment to maintaining vital regional connectors amidst the challenges of aging infrastructure and heavy traffic volumes in the Philadelphia metropolitan area.
Complex Logistics and Safety Engineering
Executing a project of this magnitude on a bridge that soars nearly 200 feet above the water requires sophisticated engineering and rigorous safety planning. Rebecca Clark, vice president of operations at Skanska USA Civil, emphasized that safety is the top priority, relying on skilled union craft workers adept at operating at significant heights. To protect both the workforce and the environment, crews are constructing temporary platforms beneath the bridge deck to prevent materials from falling into the Delaware River, while additional platforms above the roadway provide secure access to the bridge’s upper trusses.
The team is utilizing a combination of traditional methods and cutting-edge technology, including drones, to inspect hard-to-reach areas up to 80 feet in the air, ensuring that every structural deficiency is identified and addressed without putting workers at unnecessary risk. Furthermore, the project incorporates sustainability measures such as the use of battery-powered tools to reduce tripping hazards and equipment powered by renewable diesel.
Structural Reinforcement and Modernization
The scope of work involves a meticulous overhaul of the bridge’s steel components to counteract decades of wear and environmental exposure. Skanska’s team will replace approximately 60,000 pounds of steel, install 8,300 high-strength bolts, and execute structural repairs on 251 girders. A critical aspect of the rehabilitation includes the replacement of the bridge’s “wind pin,” a vital component that stabilizes the massive structure while allowing for necessary lateral movement during high winds.
The project also addresses the bridge’s longevity through the refurbishment and replacement of vibration absorbers on vertical columns and the reinforcement of 44 truss members. Once structural repairs are complete, the steel will be coated with a premium Sherwin-Williams system designed to withstand the harsh Northeast climate, followed by epoxy and polyurethane layers to shield against ice, salt, and rain.
Enhancing Connectivity and Electrical Systems
Beyond structural steel work, the rehabilitation includes significant upgrades to the bridge’s electrical and support systems. Subcontractors will replace approximately 14,000 linear feet of electrical conduit and wiring, installing new systems alongside existing ones to modernize the bridge’s utility infrastructure. The project also entails cleaning and repainting steel barriers and overhead gantries, repairing concrete piers, and replacing deteriorated reinforcement bars to maintain long-term integrity, a physical strengthening that parallels financial bolstering in the sector such as the $200 million bridge loan clearing the path for Ivanhoe Electric’s Santa Cruz Copper Mine.
Managing traffic flow during these extensive operations is a logistical feat in itself; Skanska has deployed a dedicated maintenance and protection of traffic crew to monitor patterns and ensure that lane closures are executed safely, minimizing disruptions for the millions of commuters and freight haulers who rely on this essential interstate connector.
Commodore Barry Bridge Rehab Phase 3: Factsheet
Project Name: Commodore Barry Bridge Rehabilitation (Phase 3)
Location: Spanning Delaware River (Chester, PA to Bridgeport, NJ)
Client: Delaware River Port Authority (DRPA)
General Contractor: Skanska USA Civil
Contract Value: $220 Million
Award Date: January 2025
Target Completion: Q1 2028
Scope of Work
Painting: Full structural recoating with Sherwin-Williams system.
Steel Repairs: 60,000 lbs of steel replacement; repairs to 251 girders.
Structural: Replacement of wind pin; reinforcement of 44 truss members.
Electrical: Replacement of ~14,000 linear ft of conduit/wiring.
Safety/Access: Installation of containment systems and temporary platforms.
Key Stats
Bridge Length: 2.6 miles (4th longest cantilever in the world).
Traffic Volume:~15 million vehicles annually.
Height: ~200 ft above water.
