Pfeiffer Canyon Big Sur Bridge Emergency Jacking Support

Project Snapshop

Project: Pfeiffer Canyon Bridge Replacement
Location: Big Sur, California
Challenge: Support and align a 310-foot replacement bridge span
Solution: Custom jacking support tower and 100-ton jacks
Result: Controlled positioning and lowering of the new bridge span

Pfeiffer Canyon Bridge Replacement

When the Pfeiffer Canyon Bridge on Highway 1 was damaged beyond repair, crews needed a safe way to support and position the new 310-foot bridge span during installation. CH Bull supplied a custom jacking support system designed to help the contractor align and lower the bridge with precision in a difficult canyon environment.

The Challenge

After heavy rains and mudslides, two of the bridge’s center support columns were washed out and one began to fracture. The bridge was declared beyond repair and had to be replaced quickly to restore access along Highway 1.

February 2017 had 1,150 percent of its normal February rainfall causing the bridge failure
After record February rainfall, the bridge showed major structural damage.
February 11 inspection found columns fracturing
Inspection revealed severe cracking in the support columns.

Demolition and Site Conditions

The original bridge was demolished, leaving crews with a difficult work area, limited access, and a precise installation challenge. The replacement span had to be assembled and positioned across the canyon safely.

Caltrans decision to demolish the bridge
Crews demolished the original bridge after it was declared beyond repair.
Demolition proved to be difficult
Demolition revealed the difficulty of working in the narrow canyon area.

The CH Bull Solution

CH Bull designed a custom jacking support tower and supplied 100-ton jacks to help support, align, raise, and lower the new bridge span. The system was built around the contractor’s installation conditions, including limited clearance and uneven site conditions.

30 foot sections of the steel girder were bolted together
30-foot steel girder sections were bolted together to form the new bridge span.
Construction of the new 3 girder 1000 ton structure
The 1,000-ton replacement bridge structure was assembled near the canyon.
Temporary structure with rollers and jacks to alien the launch
A temporary support tower with rollers and jacks helped guide the bridge launch.
Temporary structure to support bridge being launched
The temporary structure supported the 1,000-ton span during launch.

Precision Alignment and Final Placement

Because the bridge needed to move laterally in both directions, steel plates and rollers were used to help guide the span into proper position. C.H. Bull’s jacking expert, Stan Sheppard, was onsite during the lowering portion of the project to support the contractor’s team.

Bridge positioned over 15’ high stacks of 12 x12 dunnage
The span was supported on 15-foot dunnage stacks during positioning.
Jacks bolted to the structure key part of design
Bolted jacks provided controlled lift and adjustment.
4 pair of 100 ton jacks on each end of the bridge
Four pairs of 100-ton jacks were used at each end of the bridge.
3’ x3’ x1” thick steel plate to spread the load over the dunnage
Steel plates helped spread the load across the dunnage.
September 6th the new bridge positioned on the bearing pads
Final placement on bearing pads.

Project Outcome

With the custom jacking system in place, the contractor was able to make controlled adjustments and lower the 1,000-ton bridge span into its final position. The setup allowed the team to move the bridge laterally and align it accurately before placing it on the bearing pads.

C.H. Bull’s onsite support helped the contractor manage a complex field challenge in a restricted canyon environment, contributing to the successful replacement of a critical section of Highway 1.

October 13th the bridge re-opened only 8 months after closing
The bridge reopened on October 13, only eight months after closing.

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