Fern Hollow Bridge Emergency Replacement Project

Photo Credit: Swank Construction Company, LLC

The Fern Hollow Bridge Emergency Replacement Project exemplifies the power of collaboration, innovation and swift action in the aftermath of an unexpected catastrophe. On the snowy morning of January 28, 2022, the 447-foot-long Fern Hollow Bridge in Pittsburgh collapsed, plunging nearly 100 feet into a park ravine. Remarkably, despite the gravity of the incident, there were no fatalities. Part of the National Highway System, the bridge was a critical arterial route for vehicular and pedestrian traffic, including emergency services and mass transit. The urgency to restore this critical connection demanded a design-build approach that could deliver a solution rapidly and efficiently. Using Progressive Design-Build procurement allowed the project team to integrate design and construction from the outset, enabling rapid decision-making and efficient execution.

A Collaborative Triumph in the Face of Disaster: Rapid Response and Resilient Design

From the moment of collapse, a coordinated response was set into motion. The Pennsylvania Department of Transportation (PennDOT) took the lead, with Swank Construction Company and HDR stepping up as the design-build team. The project, which typically would have taken five years to plan, design and construct, was completed in just over 10 months — an achievement made possible by the seamless integration of design and construction efforts, just-in-time design delivery and continuous collaboration among stakeholders.

The team overcame several challenges throughout the process, including complex site conditions, environmental permitting and evolving project requirements. The new 460-foot-long, four-lane bridge restored vital transportation links and enhanced pedestrian connectivity and multi-modal transportation options, addressing the community’s needs for safer access and mobility.

The project’s success has prompted PennDOT to re-evaluate its procurement processes with an eye to adopting more design-build best practices in future projects. This project demonstrates how design-build best practices, when applied under pressure, can result in a project delivered ahead of schedule, under budget and with lasting community benefits.

Winner – Best in Small Projects (Progressive Design-Build – Horizontal)

“This is a great example of Design-Build in crisis,” remarked the awards jury. Completed in under 11 months – much faster than the typical five-year timeline – this project was completed under budget at $22 million, a small budget for a major bridge replacement. ​Progressive Design-Build facilitated seamless collaboration, rapid decision-making and efficient problem-solving without sacrificing innovation and design excellence. The new bridge, designed to eliminate expansion joints, reduces maintenance and extends its service life beyond 100 years. This project set a new benchmark for PennDOT, showcasing the benefits of design-build and prompting the agency to reevaluate its project delivery methods for future infrastructure projects.

Design-Build Team

Photos