Portageville Bridge Replacement

For Josh Munzek, serving as a Field Engineer on the Portageville Bridge Replacement meant more than working on a rail bridge, it meant contributing to a once-in-a-generation structure in one of the most scenic construction environments in the country.

“We had a great project team, the bridge and scope of work were challenging, and I was able to go to work in Letchworth State Park every day.”

The Portageville Bridge is a vital link along Norfolk Southern’s Southern Tier Line, crossing the Genesee River Gorge 235 feet above the river floor. The original iron bridge, constructed in 1875, had become a major issue due to age and structural limitations, restricting trains to just 10 mph and limiting car weights. In 2015, American Bridge was awarded the contract to replace the historic structure with a modern solution.

The new bridge was constructed on a parallel alignment approximately 75 feet south of the original span. It features a 483-foot steel arch main span, six 80-foot girder approach spans, and a total length of 963 feet, supporting a ballast-filled concrete deck. Notably, the arch spans the entire gorge, leaving no permanent footprint in the Genesee River, restoring the river to its natural state for the first time in more than 170 years.

For Josh, the project stood out because of its variety of work. It was the first time he was exposed to nearly every major discipline on a single job; blasting and excavating the gorge walls, micropile foundations, mass concrete placements, complex temporary works for steel erection, deck pours, and demolition of the existing bridge.

As Field Engineer, Josh was responsible for construction surveying of the new structure, closely monitoring the arch and tieback system through each phase of steel erection. With limited prior surveying experience, he quickly developed a new skill set under strong mentorship.

Following completion of the main structure, Josh developed the demolition plan for the original bridge, closing the chapter on a crossing that had served rail traffic for nearly 140 years.

Today, the new bridge represents a significant upgrade in rail performance. Norfolk Southern can now operate 286,000-lb railcars, up from 273,000 lbs, and trains travel across the gorge at 30 mph, tripling the speed allowed on the old structure.

American Bridge served as general contractor, self-performing all structural steel erection along with demolition of the existing bridge and foundations. The team mobilized in December 2015, and the new Portageville Bridge opened to rail traffic on December 11, 2017.

For Josh, the lasting lesson from the project is simple: the smallest details matter. Quality checks, crew feedback, cross-checking work, and thoughtful access planning all played a role in the project’s success, proof that great engineering is built as much on precision and teamwork as it is on steel and concrete.