The Wisconsin Department of Transportation (WisDOT) is facing future demands for highway bridge deck replacements on heavily used portions of its interstate highway system, particularly in the Milwaukee area. Typical bridge rehabilitation projects cause safety concerns and disruptions to traffic, and bridge closures have an adverse impact on the regional economy. WisDOT is focusing on prefabricated bridge systems for its highway bridge rehabilitation projects. The University of Wisconsin–Madison worked with WisDOT and Alfred Benesch & Co. to develop and design a prefabricated, full-depth concrete deck system for a major highway where minimal disruption to traffic flow is a requirement. In this article, the authors describe the research proposals, teamwork, design challenges, and construction of an innovative bridge redecking and widening project on westbound Interstate 90 over Door Creek in Wisconsin. The unique advantages of this hybrid prestressed, posttensioned deck panel system are the result of an innovative design that essentially ties all the precast concrete deck panels together to minimize cracking, uses a novel longitudinal joint and unique strand coupling across the joint, and minimizes traffic disruption in a rapid erection scheme.
