The Missouri Department of Transportation (MODOT) set an ambitious goal to replace dozens of rural county bridges within a budget of $26 million. All the bridges being replaced were weight-restricted, supported by timber piles, in poor condition, and were one lane carrying two-way traffic. Ultimately, they successfully replaced 31 structures, including 27 steel-supported bridges, all supplied by DeLong’s, Inc., a premier bridge fabricator based in Missouri. The Farm Bridge Project’s total bridge weight was 527 tons, with all components hot-dip galvanized for durability. One standout bridge, located on Missouri Route Y over Hoover Creek in Macon County, was 115 feet long, weighed 21 tons, and featured 12 main girders and 15 channel diaphragms. This location, about 100 miles north of DeLong’s headquarters in Jefferson City, underscores the project’s regional impact.

Infrastructure corrosion remains a persistent national issue, despite significant funding through the Infrastructure Investment and Jobs Act (IIJA). State Departments of Transportation (DOTs) face the challenge of maximizing limited resources to address critical infrastructure needs. MODOT’s Farm Bridge Project exemplified how strategic planning, and innovative approaches can overcome these challenges. By adopting the Simple for Dead Load and Simple for Live Load (SDCL) bridge design method, MODOT delivered impressive results. SDCL simplifies construction, maximizes material efficiency, reduces costs, and enhances durability with hot-dip galvanized steel, all while minimizing commuter disruptions by maintaining access to vital bridgeways during construction.

To execute this project, MODOT partnered with DeLong’s, Inc., leveraging their expertise from the early planning stages. DeLong’s Vice President of Engineering, Gary Wisch, and his team addressed MODOT’s key concerns about corrosion protection and long-term durability. While competing proposals included mixed steel-and-concrete or all-concrete designs, DeLong’s distinguished itself by exclusively using hot-dip galvanized steel. This approach ensured superior corrosion resistance and longevity, ideal for rural infrastructure with limited maintenance budgets.

DeLong’s collaborated closely with their preferred galvanizer to ensure project success. This partnership focused on optimizing designs for galvanizing, achieving uniform coating coverage, and masking specific steel surfaces to facilitate safe and efficient field welding. Precise staging and timely delivery of materials were critical to MODOT’s phased construction approach, where half of the bridge remained operational while the other half was replaced or repaired. This seamless coordination allowed DeLong’s to meet project timelines and minimize commuter disruption.

The Farm Bridge Project’s completion smashed initial expectations. In fact, It has since become a model for other DOTs, demonstrating how innovative design methods like SDCL, coupled with strategic partnerships and durable materials, can stretch budgets and deliver robust infrastructure solutions. The use of hot-dip galvanized steel not only extended the bridges’ longevity but also reduced long-term maintenance costs. MODOT’s success has earned widespread recognition, including invitations to present their approach at industry conferences and share their insights with other DOTs nationwide.

This project underscores the importance of collaboration, innovative design, and durable materials in addressing infrastructure challenges. By choosing hot-dip galvanized steel and employing the SDCL method, MODOT, DeLong’s, and their galvanizer delivered a lasting and cost-effective solution for rural communities. The Farm Bridge Project sets a new benchmark for infrastructure initiatives, proving that thoughtful planning, strong partnerships, and cutting-edge engineering can bridge the gap between funding constraints and critical infrastructure needs for decades to come.