CEE
2025-2026
Winter
Spring
Industry Sponsored

Caltrans Bridge Design: Siempre Viva Road Overpass

Siempre Viva Road overpass between SR-11 and Otay Mesa East Port of Entry

Summary

The bordering countries of the United States and Mexico are growing rapidly, both internally and externally, within their trade engagements. The current movement of goods, services, and people at the San Diego-Baja California border is becoming inadequate to suit these needs. A connecting road between California State Route 11 (SR 11) and Otay Mesa East Port of Entry (OME POE) is constructed to better suit expansion in the region. The project serves to improve movement across the border, particularly by reducing vehicle wait times. Additionally, gas emissions produced by the transportation of goods, services, and passengers will be reduced. As the area is expected to remain running for years, the project is also set to support economic growth by creating additional job opportunities near the border.

The portion assigned to Connect & Carry Co. is a smaller component of the overall project, the design of a 320 ft. two-span concrete bridge on Siempre Viva Road. Two 160 ft. spans are optimal for considerations of construction time, cost, and structural integrity. The bridge will primarily be built using pre-stressed cast-in-place reinforced concrete box girders. The superstructure includes a deck resting on box girders. The superstructure rests on the bridge seat, a shelf-like surface of the abutment directly supporting it. The bridge understructure includes columns, bent caps, abutments, wingwalls (which protect the sides of the abutments), foundations, and piles (where applicable). The bridge is post-tensioned with strands inserted into ducts to create cambering, which better resists gravity loads. Expansion joints, a gap left between each span, are used in the bridge to allow for self-equilibrium when experiencing expansion or contraction (a common occurrence due to phenomena such as material responses to temperature changes). The design should accommodate dead loads (self-weight), live loads (such as travelling vehicles), service loads (expected daily loads such as wind), and extreme events (seismic forces, within California). Leading up to the bridge, an approach slab smooths the transition from roadway to bridge and limits the settlement of roadway sediment directly next to the bridge, instead transferring vertical forces to a distance before the bridge and preventing damage to bridge joints. An alignment for the road and geotechnical reports for the soil are provided to Connect & Carry Co. for design purposes. The final bridge design includes two-way lanes and safety details such as a chain fence enclosure used to prevent objects from falling or being thrown onto the road and causing obstructions.

Technical Approach/Methodology

Connect & Carry Co. designed a two-span concrete bridge on Siempre Viva Road. Referencing AASHTO LRFD and Caltrans adjusted standards, calculations were made to determine the style and dimensions of each bridge component. Designers used Load and Resistance Factor Design (LRFD) to identify load demands and to design the bridge with necessary load capacity. 

Connect & Carry Co. designed by following the load path of the bridge in a top-down design structure, beginning with the superstructure (deck, box girders). Next, the bents, bent caps, and abutments were designed. Finally, the columns, foundations, and piles (if needed as part of the foundation system) were designed. At each step, the dead weight of the structure above and the live weight of the vehicles utilizing the bridge were considered, as well as weather and hazardous (seismic) concerns. Accordingly with Caltrans seismic design standards, the bridge follows a “strong beam weak column” philosophy wherein essential structural components requiring access during an emergency event, such as the superstructure, remain capacity-protected while sacrificial elements such as shear keys and backwalls disengage to resist forces and prevent forces travelling to critical members. Earthquake resisting elements such as columns are designed with specified areas where plastic hinges should form at the ends to deform and dissipate seismic energy. The bridge is idealized as a Single Degree of Freedom (SDOF) structure for these checks. Finally, detailed elements such as expansion joints to adjust for the bridge’s temperate expansions and contractions were considered. 

Components of the bridge, as well as the entire bridge structure, were modelled within the analytical modelling software CT Bridge for design capacity checks. The entire Siempre Viva bridge was also modelled within the Building Information Modelling (BIM) software Navisworks for precision coordinates, improved construction, and better information exchange between all teams. All modelling information was provided by Caltrans advisors. 

Outcomes

Connect & Carry Co. delivered a complete preliminary bridge design for the Siempre Viva Road overpass, following Caltrans adjusted AASHTO standards to identify the component types and dimensions of the superstructure deck, box girders, bents, bent caps, abutments, columns, and foundation. Design checks followed LRFD protocol and referenced AASHTO and Caltrans standards. A complete load analysis was performed, accounting for vertical loads (such as vehicles and the structure dead weight), lateral loads (such as wind and seismic), and additional bending, flexure, and moment from specific components. Connect & Carry Co. additionally considered project feasibility (such as the ability to transport structural components and the accessibility of components mid-construction), tabled exact dimensions and component styles, provided hand calculated demand vs. capacity checks, and provided analytical models which corroborated the design. A Building Information Model (BIM) was also provided to facilitate collaboration between structural designers, construction crews, surveyors, and architects). Both analytical and visual models provide a developed summary of the bridge’s expected performance and visual appearance. Alternative solutions were considered on a case-by-case basis with options to consider for a more conservative design or if geotechnical and landscape conditions changed. Connect & Carry Co. finalized the report by recommending next steps for a more comprehensive analysis with greater detailed design of each component.

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