Port Mann Highway 1 Improvement

Location: Vancouver to Langley, BC 
Owner: Kiewit Flatiron GP
Completed: June   2012
Value: $20M

Since the beginning of construction in 2009, GIG was involved as a preferred subcontractor to the Kiewit Flatiron GP (KFGP) Design-Build team, for the replacement of the original Port Mann Bridge and upgrading of 37km of Highway 1 from Vancouver to Langley.  Primary activities included the construction of replacement overpass structures across Highway 1 at 160th Street and 104th Ave in Surrey. Additionally, GIG has provided utility protection and relocation services throughout the Port Mann/Highway 1 (“PMH1”) corridor, including relocation of City of Surrey trunk sanitary  sewers and watermains for the environmentally sensitive 176th Street and 104th Avenue intersection reconstruction.
As a provincial design-build project, the Project was required to develop and administer a comprehensive Quality Management Plan covering all aspects of design and construction. GIG was required to adhere to this plan and provide all documentation and third party QC testing to satisfy project requirements. In order to keep the existing overpass structures open to traffic until completion of the new overpasses, the new structures were designed to be built immediately adjacent to the old. This required development of site specific temporary shoring to support the 50 year old overpasses while bridge end fills and abutments were constructed for the new structures, arm’s length from the existing. The project required construction of MSE walls for abutment support immediately next to an operating freeway. This required coordination of traffic staging and detours to allow for safe placement of precast bridge deck girder over top of existing highway.

Project Innovations:

  • combining various temporary retaining wall designs to allow for protection and support existing structures during construction
  • use of custom concrete and galvanized steel split casings to protect in service municipal utilities to allow for highway widening
  • staged deep foundation peat excavation and replacement with light weight fills to allow for replacement of municipal trunk utilities under roadways avoiding the cost of piled foundation.

GIG was required to comply with the stringent project-wide Environmental Management
Plan, specifically sediment control, and control and treatment of concrete wash.  The two
overpass structures bookend a fisheries watercourse which required regular monitoring and
protection. Further, GIG adhered to the PMH1 safety program developed for the project by
KFGP to specifically address the safety concerns of working in close proximity to high
volume traffic.