Background The original Evergreen Point Floating Bridge, also named for state governor
Albert D. Rosellini, opened on August 28, 1963, carrying the four-lane
State Route 520 (at the time designated temporarily as the Evergreen Point branch of
Primary State Highway 1 until the
1964 state highway renumbering). The floating span consisted of 33 pontoons and cost $24.7 million to construct (equivalent to $ in ); the bridge carried four lanes of traffic, separated by a curb that was later replaced with a simple
Jersey barrier; at the center was a drawspan that opened for large vessels traversing the lake. The original bridge would also close to traffic during sustained
wind gusts of or higher for more than 15 minutes. The Eastside is also served by the
Interstate 90 floating bridges completed in 1940 and 1989, carrying traffic across
Mercer Island to and from Bellevue. The original Evergreen Point Floating Bridge was designed before the implementation of modern
earthquake engineering standards, with vulnerabilities in its hollow support structures that could have failed in a major earthquake. Additionally, near the end of its lifetime,
vibrations induced by
storm surges and strong winds were able to compromise the aging drawspan, anchor cables, and pontoons, leading to structural failure in a major
storm. The study followed several others in the late 20th century to find solutions to traffic on the SR 520 floating bridge, with most proposals rejected after heavy opposition from communities on both ends of the bridge. The preferred alternative for the bridge's design, with four general-purpose lanes and two HOV lanes, was announced by WSDOT in April 2010. Alternative options included the construction of a southbound onramp from the
I-5 express lanes, the addition of light rail to the project, and an eight-lane bridge. The final
environmental impact statement for the project was issued in 2011, allowing for construction of the pontoons to begin the following year. Funding was allocated to major phases of the project at different times. The western portions of the project in Seattle, which are budgeted at $2 billion, were the last to be funded as part of the 2015 and 2022 legislative transportation packages.
Construction The first stage of the SR 520 floating bridge replacement project was the construction of 77 concrete pontoons in 2011 and 2012 by
Kiewit-General-Manson at two purpose-built facilities in
Aberdeen and
Tacoma. The pontoons were floated to the bridge on Lake Washington via the
Lake Washington Ship Canal. Pontoon assembly and fastening, to form the floating bridge's deck, began in 2014 and concluded in July 2015. In 2012, WSDOT identified cracks and other problems with the first batch of completed pontoons, estimating that it would cost $400 million to repair cracks and other flaws that would bring down the bridge's predicted lifespan below the desired 75 years. The problems were originally speculated to stem from shortcuts allegedly taken by the contractor to complete pontoons to meet set deadlines; the proposed solutions to fix the pontoons included adding high-tension steel cables and
post-tensioning of the concrete. A state investigative report by concrete expert John Reilly blamed the WSDOT Bridge and Structures Office (BSO) for the error. The BSO did most of the pontoon design in-house, instead of delegating those details and the financial risk to contracting teams. The goal was to allow bids to be submitted sooner. The states top bridge engineer, Jugesh Kapur was ultimately let go over the error and another Department of Transportation employee was demoted. A floating,
cofferdam was launched in November 2013 to assist in repairs of the pontoons, functioning as a portable
drydock that wrapped around parts of the pontoons. The repairs were made by the contractor at the direction of WSDOT from December 2013 to June 2014 and cost a total of approximately $208 million, using up the majority of the program's reserve funds. As a result of the pontoon issues, the estimated opening of the bridge was pushed back from December 2014 into 2016. In March 2015, two construction accidents on the bridge slowed construction for reevaluation of safety measures: a contractor was killed after a high fall on the east highrise; and a crane-lifted load of
steel pipes swung out of control into a
King County Metro bus and an overhead highway sign. The bridge deck was lifted into place in August 2015, and the final concrete pour was finished in October 2015, completing the bridge deck. ==Operational history==