One small hole can quickly turn into a bridge closure.

Kevin Gray and his crew work hard to avoid this situation by using a combination of strategic bridge inspections and replacements to keep Butler County’s bridges safe.

Gray, the county’s bridge and fleet manager, pointed to the Fern Hollow Bridge collapse in Pittsburgh in 2022 as the perfect example of why he and his five-person crew prioritize inspection and maintenance to prevent that kind of disaster from occurring here.

“When Fern Hollow happened, I think we were the only ones focused on where are the lessons learned? Where were the municipal and county failures so we could make sure that never happens here,” Gray said. “We have a capital improvement plan that we work through. We’re not going to be surprised.”

Part of the plan includes inspections and maintenance on a rotating schedule. Inspections provide the data needed to anticipate where deterioration is happening and how to stay ahead of it.

The bridge inspection protocol calls for the inspection of county bridges over 20 feet every two years. Structures under 20 feet receive a checkup at least every five years. SAI Engineering, contracted through the state Department of Transportation, inspects all county bridges over 20 feet. Herbert, Rowland and Grubic, the county’s engineer of record, handles all other bridges.

Mark Gordon, county planning commission chairman, called Gray and his crew a tremendous asset to the county. He said the team collects extensive data about every bridge in the county and has an aggressive plan to deal with any issues.

“There are eyes on it. There’s a disciplined approach, which is why we’re so much better off than surrounding counties,” said Gordon, adding that Gray is recognized by his peers as a subject matter expert for his innovative methods and fiscal responsibility.

Weather events and vehicle accidents significantly impact the safety ratings and structural integrity of bridges.

“Floods, high water, a vehicle accident that causes a fire or explosion on a bridge — any of these things can cause a fair-rated bridge to decline into the poor category,” Gray said. “Many bridges currently listed in our poor rating category were event-driven.”

Floodwaters erode the sediment around bridge foundations, creating scour holes that compromise structural stability. Scour is the leading cause of bridge failure in the U.S. Meanwhile, high temperatures can accelerate material degradation, particularly in steel bridges.

Gray said vehicle collisions with bridge components are another common problem. Some accidents might go unreported. Damage is not discovered until an inspection is conducted. Even with reported accidents, insurance might only cover the immediate damage caused without accounting for other compounding issues.

“That’s why any time we make repairs after an accident, we reinspect the entire bridge to make sure no other structure components were impacted that could change that safety rating,” Gray said.

Butler County officials have implemented a comprehensive approach to bridge maintenance that prioritizes safety while carefully managing taxpayer resources. This strategy combines rigorous inspection protocols with innovative funding mechanisms to address infrastructure needs across the county.

Gordon emphasized the proactive stance taken by the current administration. “With this group of county commissioners, we have taken a very aggressive approach with all of the municipalities where we provide significant resources.”

The county has developed specialized funding programs to help municipalities address infrastructure challenges that exceed their operating budgets. Gordon highlighted a particularly effective fiscal measure.

“You’ve got to give the county commissioners credit. They did something unpopular by enacting that $5 fee. However, that fee has generated $1.3 million for the county,” he said.

This revenue proved instrumental in securing a $2 million federal grant for the Kelly Bridge replacement project, which carried a total cost of $2.4 million.

“So, basically, we’re getting a new bridge for $400,000,” Gordon noted, illustrating the county’s ability to leverage local funds for maximum impact. “When I say there’s a disciplined approach here, it’s not just in inspection frequencies. It’s also how to be fiscally responsible, how to maximize the amount of leverage that you get out of county dollars.”

Gray points to tangible results from this approach, with the county assisting municipalities in constructing eight bridges over the past 12 years, in addition to funding various repair projects. This commitment extends to maintaining safety standards for all bridges in the county, regardless of jurisdictional boundaries.

The county further enhances cost efficiency by eliminating intermediaries in the procurement process. By directly purchasing materials such as steel beams rather than relying on contractors as middlemen, Butler County achieves significant savings while maintaining high standards for infrastructure safety, he said.

Two county-owned bridges — Kelly and Keister bridges in Slippery Rock Township — are slated for replacement this year, Gray said.

Kelly Bridge is a 93-foot span. The total cost for replacement is $2.4 million, with $2 million in federal grants helping to cover the cost.

Keister Bridge is a 50-foot span that will cost $650,00 to replace. A Pennsylvania Infrastructure Bank loan was granted to cover the costs.

In addition to these replacements, the Snake Bridge in Parker Township — with a span of 25 feet — will be rehabilitated at a total cost of $60,000. Liquid fuels fund will be used to cover the costs.

Motorists can stay informed

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Residents can check conditions and active roadwork on major roads by visiting www.511PA.com. The free service provides traffic delay warnings, weather forecasts, traffic speed information and access to more than 1,000 traffic cameras.

It’s also available through a smartphone application for iPhone and Android devices, by calling 5-1-1, or by following local alerts on X.

Butler County residents can subscribe to PennDOT news for Armstrong, Butler, Clarion, Indiana and Jefferson counties at www.penndot.pa.gov/District10 or find updates on X, Facebook and Instagram.

Gray and his team aren’t the only ones responsible for maintaining Butler County bridges. PennDOT is responsible for roughly 25,400 bridges statewide. Engineering District 10 — which covers Armstrong, Butler, Clarion, Indiana and Jefferson counties — includes 1,630 bridges.

Butler County residents will notice significant infrastructure improvements underway as PennDOT advances several important bridge replacement projects throughout the region. These projects represent critical investments in public safety and transportation reliability for the growing community, said Tina Gibbs, PennDOT District 10 community relations coordinator.

Currently, PennDOT is focused on several key bridge replacements in the county, including the Callery Bridge project in Callery and Adams Township. The $4 million project began April 1 with crews paving the northbound shoulder of Mars-Evans City Road between the intersections of Kline Avenue/Marburger Road and Center Street.

“This project will be constructed in phases to allow for one-lane traffic controlled by a temporary traffic signal,” Gibbs said. “The contractor will maintain access to all driveways, local roads and businesses throughout construction.”

The Callery Bridge project, being completed by Chivers Construction Co. of Fairview, represents the second of two bridges being replaced at the location, with the first successfully completed in 2024. The current phase is estimated to be completed by November.

Another significant project is the Karns Crossing Bridge replacement, a $64.8 million investment that will replace two separate structures: The bridge that carries Route 68 over railroad tracks and an adjacent arch culvert over the waterway. This comprehensive project also includes traffic safety and capacity improvements at nearby intersections, Gibbs said.

In April, crews closed Delwood Road and began constructing a temporary road with detours in place until November, she said. Nighttime single-lane traffic restrictions are planned for Route 68 for water, gas and sewer line work throughout the summer.

Swank Construction Company, of New Kensington, is handling the complex project, which isn’t expected to be completed until spring 2028, highlighting the scale and importance of the infrastructure improvement.

PennDOT points to age and condition assessments as primary factors for bridge replacement. The department maintains a comprehensive bridge inspection program that identifies structures in need of repair or replacement before they become safety concerns.

Looking ahead, the Geibel Road Bridge, a local Butler County-owned structure, is scheduled for spring 2026 construction. The project will replace the existing bridge with an improved alignment of Geibel Road, Gibbs said.

Modern bridge design incorporates numerous improvements over older structures.

“Our standards take into account the use of maintenance-reducing materials and longevity considerations in design and construction,” Gibbs said. “The new bridges will use galvanized beams and epoxy-coated reinforcement bars to help protect against corrosion and extend their service lives.”

Safety improvements are also central to the new designs. The replacement bridges will be wider than existing structures and feature updated bridge railing and guide-rail systems that meet current safety standards.

Environmental considerations play a role as well. The Callery Bridge project, for example, incorporated a stream channel improvement plan that reestablished and improved the stream channel between the two structures.

“These stream restorations are to decrease the sediment loads of the watercourses and improve overall water quality,” Gibbs said.

Additionally, where possible, new bridges are constructed above the 100-year flood elevation, she said. The Geibel Bridge project will include raising the road and bridge deck, and providing a wider stream opening to better handle future flood events.

Weight restrictions also often limit commercial traffic on aging bridges. The Geibel Bridge, for instance, is currently posted with a weight restriction that prohibits trucks heavier than 15 tons. Once replaced, the new bridge will have no weight restrictions, improving transportation efficiency for businesses in the area, Gibbs said.

This article originally appeared in the May edition of Butler County Business Matters.