The original Evergreen Point Floating Bridge was designed before the implementation of modern earthquake engineering standards, with vulnerabilities in its hollow support structures that could have failed in a major earthquake. Additionally, near the end of its lifetime, vibrations induced by storm surges and strong winds were able to compromise the aging drawspan, anchor cables, and pontoons, leading to structural failure in a major storm. Even if the storms were below the maximum threshold for failure to occur, Washington State Department of Transportation (WSDOT) would still close the floating bridge to traffic. Although the original bridge carried two lanes of traffic in each direction, it did not include shoulders or pedestrian and bicycle infrastructure. The lack of a shoulder led to traffic congestion in the event of an accident, which would block one or two lanes in a given direction and block emergency services from accessing the bridge.
Planning of the replacement bridge started in 1997 with a cross-lake study conducted by the state Department of Transportation. The study followed several others in the late 20th century to find solutions to traffic on the SR 520 floating bridge, with most proposals rejected after heavy opposition from communities on both ends of the bridge.
The preferred alternative for the bridge's design, with four general-purpose lanes and two HOV lanes, was announced by WSDOT in April 2010. Alternative options included the construction of a southbound onramp from the I-5 express lanes, the addition of light rail to the project, and an eight-lane bridge. The final environmental impact statement for the project was issued in 2011, allowing for construction of the pontoons to begin the following year.
Funding was allocated to major phases of the project at different times. The $4.5 billion in funding comes largely from the state gas tax earmarked for highways in 2005, toll revenue, and federal highway funds and loans. In 2014, the budget for the project was increased by $250 million to cover cost overruns. The western portions of the project in Seattle, which are budgeted at $2 billion, were the last to be funded as part of the 2015 and 2022 legislative transportation packages.
The first stage of the SR 520 floating bridge replacement project was the construction of 77 concrete pontoons in 2011 and 2012 by Kiewit-General-Manson at two purpose-built facilities in Aberdeen and Tacoma. The pontoons were floated to the bridge on Lake Washington via the Lake Washington Ship Canal. Pontoon assembly and fastening, to form the floating bridge's deck, began in 2014 and concluded in July 2015.
In 2012, WSDOT identified cracks and other problems with the first batch of completed pontoons, estimating that it would cost $400 million to repair cracks and other flaws that would bring down the bridge's predicted lifespan below the desired 75 years. The problems were originally speculated to stem from shortcuts allegedly taken by the contractor to complete pontoons to meet set deadlines; the proposed solutions to fix the pontoons included adding high-tension steel cables and post-tensioning of the concrete. A state investigative report by concrete expert John Reilly blamed the WSDOT Bridge and Structures Office (BSO) for the error. The BSO did most of the pontoon design in-house, instead of delegating those details and the financial risk to contracting teams. The goal was to allow bids to be submitted sooner. The states top bridge engineer, Jugesh Kapur was ultimately let go over the error and another Department of Transportation employee was demoted. A floating, 660-short-ton (600 t) cofferdam was launched in November 2013 to assist in repairs of the pontoons, functioning as a portable drydock that wrapped around parts of the pontoons. The repairs were made by the contractor at the direction of WSDOT from December 2013 to June 2014 and cost a total of approximately $208 million, using up the majority of the program's reserve funds. As a result of the pontoon issues, the estimated opening of the bridge was pushed back from December 2014 into 2016.
The bridge deck was lifted into place in August 2015, and the final concrete pour was finished in October 2015, completing the bridge deck.
Traffic on the new bridge was shifted over in two stages, beginning with westbound traffic on April 11 and ending with eastbound traffic on April 25. Initially, the bridge narrowed from 6 lanes to 4 lanes at the end of the floating span, over 1.2 miles (1.9 km) east of the Montlake Boulevard interchange, and was not fully traversable for bicyclists and pedestrians. Shortly after the opening of the bridge's westbound lanes, the Washington State Transportation Commission proposed increasing toll rates to introduce nighttime tolling by 2017. The toll rate increase and nighttime toll was approved by the commission and implemented on July 1, 2017.
The old bridge was planned to be decommissioned by floating away pontoons to an industrial site in Kenmore for disposal and recycling; in March 2016, the city rejected the plan, citing the possible release of toxins in the pontoon's concrete. The pontoons were sold to a recycling company based in Gig Harbor which plans to reuse the individual pontoons for floating decks and other projects. An unaffiliated contest was held in 2012 seeking ideas for the 33 pontoons of the old bridge, with solutions ranging from a "floating High Line" to partial submersion for walking paths. The first pontoon of the old bridge to be disassembled was towed through the Lake Washington Ship Canal in July 2016. As of December 2020, several pontoons of the old bridge are anchored in the Pitt River in Pitt Meadows, British Columbia.
Construction of the 1.2-mile (1.9 km) western approach to the floating bridge, a conventional viaduct that crosses Union Bay, was split into three projects. A temporary bridge to connect the new floating bridge to the existing western approach was completed in September 2014. The north side of the new western approach, which would ultimately carry westbound traffic and the multi-use trail, began construction in October 2014. The project included removal of unused ramps over SR 520 that were built in the 1960s for the cancelled R.H. Thomson Expressway project; the ramps were demolished the following month, with the exception of a single set of four columns preserved for a future park, to make way for a work platform. The new approach bridge opened for westbound traffic in August 2017, with later revisions to extend the HOV lane towards the Montlake interchange. The bridge's multi-use bike and pedestrian path partially opened in July 2016, with access to the completed sections for an "out-and-back" experience; the trail was fully opened on December 20, 2017.
The original approach bridge continued to carry eastbound traffic until it was closed in November 2019 to prepare for construction of the south half of the new approach bridge. All four lanes of traffic between Montlake Boulevard and the floating bridge was directed onto the westbound approach bridge, which was narrowed and restriped for the multi-year construction period. A temporary onramp from Lake Washington Boulevard was opened a month later to replace the last of the unused Thomson Expressway ramps. Two mobile gantry cranes were used to disassemble and lift pieces of the old approach bridge beginning in 2020 after a construction delay due to the COVID-19 pandemic. The eastbound lanes on the approach bridge were opened to limited traffic in July 2023 and expanded to carry three lanes in its permanent configuration the following month. The remainder of the SR 520 megaproject, which includes replacement of the Portage Bay bridge and Montlake Boulevard interchange, is scheduled to be completed in 2031.
The new Evergreen Point Floating Bridge was designed to be more stable in stronger winds and raised the bridge deck much higher above the surface of the lake than the old bridge. Unlike the original floating bridge, where the road surface is directly on pontoons connected end-to-end, the new bridge featured pontoons laid north–south, perpendicular to the direction of vehicular traffic, and a road surface on a platform raised 20 feet (6.1 m) above the water. This design includes shoulders and a protected pedestrian and bicycle path across the viaduct.
Of the pontoons, 21 are longitudinal pontoons that support the deck and structure and are 360 by 75 by 28 feet (109.7 m × 22.9 m × 8.5 m) and weigh 11,000 short tons (10,000 t); 54 smaller supplemental pontoons, weighing 2,500 short tons (2,300 t), are used to stabilize the weight of the bridge; and two "cross" pontoons, weighing 10,100 short tons (9,200 t), are sited at each end of the floating span at transitional spans, which connect the deck to fixed bridges and approaches using hinges to move up to 24 inches (61 cm) for fluctuations in lake water levels moving the pontoons. All the pontoons are designed with watertight compartments that are monitored remotely with sensors to detect leaks that could lead to catastrophic failure.
The bridge's 58 anchors all feature 3-inch-thick (7.6 cm), 1,000-foot-long (300 m) steel cables and are divided into three types: 45 587-short-ton (533 t) fluke anchors used in softer soils deep in the lakebed; eight 107-short-ton (97 t) gravity anchors used in solid soils nearer to the shore; and five 10-foot-diameter (3.0 m), 79-to-92-foot-long (24 to 28 m) drilled shaft anchors used in conjunction with the gravity anchors to prevent navigation hazards.
To ensure storm resistance in the event of water seeping into the pontoons, each pontoon is outfitted with a leak detection system with a float switch that sits about 3 inches (7.6 cm) off the floor. If the pontoon is breached, an alarm will sound inside the maintenance building. From there, a pump can be lowered into the chamber and controlled from the deck above.
The bridge features advanced monitoring devices and new maintenance facilities. Beneath the bridge is a three-story high brick building used to control and monitor various life support and utility systems on the bridge. A backup generator sits on the ground level to power all systems in case of power loss. Behind the back wall of the building lies a massive retaining wall built in response to steep hills.
Public transportation and high-occupancy vehicle (HOV) use were incorporated in the bridge design. The bridge includes HOV lanes with priority for transit and the program as a whole built several transit-only facilities. A 2008 WSDOT report included five core bus rapid transit routes proposed by Sound Transit connecting the Eastside (Kirkland, Redmond, and Bellevue) to Downtown Seattle and the University District, with a base frequency of 15 minutes, increasing up to 7 minutes at peak times. The bus rapid transit program was not implemented and replaced by increased frequency on King County Metro and Sound Transit Express routes that serve the corridor. Existing freeway bus stations (also known as "flyer stops") on the Eastside at Evergreen Point and Yarrow Point were rebuilt and moved from the freeway's shoulder to the median, accompanied by landscaped lids with parking and lawns, in 2014 for increased compatibility with the bridge's planned HOV lanes.
In 2023, a total of 20.48 million toll transactions were recorded, of which the average rate paid was $3.37; approximately 85 percent of toll transactions were paid through the Good to Go system. A peak of 26.5 million transactions were reported in 2019 with an average revenue of $3.48.
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