DOT orders refabrication after contractor-built bridge parts fail measurements; completion now mid‑April, liquidated damages set

City staff told the Watertown Common Council on Feb. 17 that the Wisconsin Department of Transportation determined parts of the new bridge were fabricated incorrectly and directed the contractor, ZTI, to refabricate the arches and some spandrels. Staff said the fascia girder may be refurbished and reused rather than refabricated. Refabrication work began last Monday; DOT and project staff currently expect completion in mid‑April, weather permitting. Liquidated damages for the contractor will begin March 2 at $5,000 per calendar day.

The update said DOT first identified problems with spandrels and arches in late 2024 and that a 3‑D scan provided by ZTI uncovered additional misalignments, including anchor inserts that did not line up with sleeves and a pipe sleeve issue in the fascia girder. DOT staff evaluated ZTI’s repair concepts and ultimately directed refabrication of the arches. A department office later approved a correction that would allow reuse of the fascia girder.

Andrew, a member of the project team, told council members the department had given ZTI options to investigate and that the Bureau of Structures and project staff evaluated those options before directing refabrication. “It’s our understanding that we won’t be sacrificing quality through these discussions and with what we accept as a final product,” Andrew said when asked whether repairing the fascia girder would reduce the structure’s expected service life.

Council members asked about cause and oversight. A councilor asked whether the problem was a specification error or a fabrication error; staff replied the parts were not fabricated to the plans and that the contractor failed to follow required measurement sequencing during fabrication. Council members said they were frustrated to learn ZTI had built a similar bridge elsewhere and that the city had to press DOT and the contractor for details such as as‑built measurements of the railings.

City staff said the DOT secretary’s office and the assistant deputy secretary are engaged at a high level and are working to expedite delivery. Staff asked DOT to measure the railings before delivery; DOT agreed to provide as‑built measurements. The update noted that project oversight will continue after the city’s current mayor leaves office and that additional city engineering staff will be assigned to the project.

Separately, a councilor said the city attorney will prepare a draft change‑order or relief request to DOT that could seek compensation for local businesses affected by the delay. Staff described that chance as “small” because any relief would require the state to concede a portion of liquidated damages.

Councilors did not take a formal vote on the update; the item was presented as information and to request continued staff oversight.

The council directed staff to continue close oversight of the project, to obtain as‑built measurements for railings before delivery, and to work with the city attorney on a potential change‑order or relief request for affected businesses.

The presentation and council discussion make clear the project will extend beyond the current mayor’s tenure and that DOT, the contractor and city staff will continue to be engaged until refabrication and final inspections are complete.