Metamora Bridge Replacement Project

State Routes 120 & 64 | Metamora, Ohio

In October 2024, Vernon Nagel Inc. was awarded a bridge replacement project in the Village of Metamora near the intersection of State Routes 120 and 64—a critical transportation corridor connecting communities across Northwest Ohio and serving traffic traveling between Ohio and Michigan.

The project involved demolishing the existing structure and constructing a new pre-stressed box beam bridge designed to improve long-term durability and safety while minimizing impacts to surrounding buildings and businesses.

Originally contracted at $3.9 million, the project is expected to finish at approximately $3.2–$3.3 million, delivering significant savings while maintaining the project schedule.

Project Scope

The Metamora bridge project required a complete replacement of the aging structure along with improvements to the bridge foundation and roadway approach.

Key elements of the project included:

• Demolition of the existing bridge structure

• Installation of a new waterline under the new structure

• Construction of friction-based drilled shaft foundations

• Placement of a pre-stressed box beam bridge

• Installation of a poured concrete deck and approach slabs

The bridge closure lasted approximately 120 days, temporarily impacting traffic through the village due to the importance of this route as a primary east-west connection.

Value Engineering That Delivered Significant Savings

The original design called for a three sided box culvert structure with deep foundations and driven piling, which presented significant challenges given the location of the bridge in a historic downtown area.

Several buildings more than 100 years old sit within 60 feet of the bridge, meaning pile driving could have caused damage to nearby structures.

After evaluating the design, the Vernon Nagel team partnered with engineering firm Valcon Consulting Group to develop a Value Engineering Change Proposal (VECP) that introduced a more efficient structural solution.

The revised design replaced driven piles with friction-based drilled shafts, eliminating vibration risks to nearby buildings while improving constructability. The revised design also replaced the three sided box culvert with a pre-stressed box beam design.

This solution ultimately generated more than $1 million in project savings while maintaining structural performance and schedule commitments.

Solving Complex Project Challenges

During the early stages of construction, the project team identified discrepancies within the original hydraulic and scour analysis that required additional review by the Ohio Department of Transportation and the design engineer of record.

Addressing these issues required a temporary pause in the final design process while the analysis was re-evaluated and corrected. The waterway permit also expired the day the project was bid, requiring additional coordination with environmental agencies to revise the permit.

Through strong collaboration between the project partners, the team successfully resolved these issues and kept the project moving forward.

Community Collaboration

Because the bridge is located in the heart of the Village of Metamora, maintaining clear communication with local residents and businesses was a key priority throughout the project.

The Vernon Nagel team worked directly with the village and nearby businesses to communicate construction schedules and minimize disruptions during the closure period.

Special coordination was required during the demolition of Mike’s Garage, which sits adjacent to the project site and continued operating during construction. The team worked closely with the business owner to maintain access and accommodate daily operations while safely completing demolition and construction activities.

A Successful Team Effort

The Metamora bridge replacement project highlights the importance of communication, collaboration, and innovation in infrastructure construction.

By partnering closely with ODOT, engineering teams, and the local community, Vernon Nagel delivered a modern bridge solution that improves transportation infrastructure while protecting the surrounding historic structures and businesses.

The project stands as a strong example of how proactive problem solving and teamwork can turn complex challenges into a successful outcome for both the client and the community.

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