Shirley's Big Beam Weekend

In late January, crews worked 54 consecutive hours over a single weekend to install 10 girders, each measuring close to the length of a football field, across Interstate 495 in Virginia. This work is part of the comprehensive I-495 Express Lanes Northern Extension (495 NEXT) project, which aims to alleviate congestion and enhance safety for one of the nation’s busiest highways through a two-and-a-half-mile extension of the express lanes from the Dulles Corridor to the George Washington Memorial Parkway. 

Aptly titled,“Big Beam Weekend” by the project team, the installation – which supports a new express lane ramp – required a complete shutdown of the interstate’s northbound lanes in Tysons, Virginia. Shirley Contracting Company, alongside Transurban, Lane Construction, Virginia Department of Transportation, and High Steel Structures, began careful coordination 18 months prior to the complex girder erection. 

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Designed and fabricated by High Steel Structures, each girder measures 11 feet high by up to 295 feet long and weighs up to 80 tons. On Friday night of the Big Beam Weekend, the girders were staged and lifted across the interstate’s northbound lanes. Crews then utilized a customized lifting rig to splice the girders mid-air. Once the girders were placed into final position, crews worked diligently to secure the supportive lateral cross frames that stabilized the beams in preparation for pouring the concrete deck. 

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Site conditions contributed to complex work zone logistics. Because the work was occurring directly over an existing bridge, the heavy beams and cranes could not be staged in line with the new overpass without jeopardizing the bridge’s integrity. Instead, the two cranes and accompanying staging equipment were positioned further back from the operation to protect the bridge, creating a longer path of travel for the beams’ installation. 

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Throughout the non-stop work, communication was paramount to the weekend’s success, with project leaders meeting hourly to assess progression and account for any necessary adjustments in the schedule. Despite navigating time and spatial constraints, crews safely and efficiently completed the installation with two-and-a-half hours to spare on Sunday night. “It didn’t matter your role, responsibility, or title, we were all here as a unit, with a common goal – success,” says Michael Trabucco, vice president of Shirley Contracting. 

The conclusion of the Big Beam Weekend not only marks a significant step forward for the 495 NEXT project, but also serves as a testament to the team’s resilience and determination. The new express lanes are expected to be operational by the end of 2025, with the overall project completion slated for 2026.