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Abernathy bridge update: 70% complete but schedule and fabrication issues raise cost and timing risks
Summary
ODOT reported the Abernathy I‑205 bridge retrofit is roughly 70% complete but faces schedule compliance gaps and steel fabrication delays; staff cited a favorable DRB report and proposed mitigation including a polymer grout method for sole-plate fit-up and conversion of $293M short-term borrowing to long-term bonds.
ODOT staff reported steady construction progress on the I‑205 Abernathy bridge retrofit but highlighted significant schedule and cost risks that require active mitigation.
Region 1 Manager Ryan Winsheimer (S20) said in-water substructure work and major piers are complete and the project is about 70% finished. But staff flagged two critical, ongoing risks: the contractor has not produced a contractually compliant schedule following Change Order CCO‑50, and structural-steel fabrication delays prompted a Dispute Review Board (DRB) process. Winsheimer said the DRB’s October report reached no entitlement conclusion and recommended steps to accelerate fabrication; ODOT and the contractor are now implementing recommendations.
Staff described a specific field problem—sole-plate fit-up where warped existing girders made tight machining tolerances difficult—and a proposed mitigation using an engineered metal-polymer epoxy injection to achieve acceptable bearing without an extensive re‑machining program. The commission was also briefed on financing: ODOT has used commercial paper to cash‑flow Abernathy (about $293M outstanding) and plans a bond authorization to refund short-term borrowing with HB2017 bridge/seismic-backed highway-user-tax bonds; a bond resolution (Res. 328) to convert short-term debt into long-term bonds was later approved by the commission.
ODOT said it will withhold payment if the contractor does not deliver an approvable schedule and will provide quarterly CIAC updates and more granular financial risk analysis as schedule and fabrication issues are resolved.
