Just five years after the bridge opened, a study commissioned by the state legislature was completed to figure out how to provide for the great demand for cross-lake transportation. That study evaluated bridge and tunnel crossings north and south of the bridge. Other plans considered in the late 1980s proposed the addition of rail transit or bus lanes to add capacity. To prepare a case for the state legislature, the Trans-Lake Study was commissioned to study various alternatives. The study brought together 47 representatives of public agencies, neighborhoods, businesses, and advocacy interests. In 1997, Myint Lwin, WSDOT's chief bridge engineer, said that even with repairs, the bridge could be expected to last only about twenty more years (until 2017). The bridge needed to be closed to traffic in high winds, and even after a seismic retrofit in 1999, it was at risk of collapse during an earthquake. Due to the weight of various reinforcements over the years, the bridge deck ultimately sat about lower over the water than it did originally. Since the bridge was built in the early 1960s, prior to the implementation of modern earthquake standards, its hollow support structures would have likely failed during a major earthquake. Additionally, vibrations induced by storm surges and strong winds could have compromised the drawspan, anchor cables, and pontoons, subjecting them to structural failure. Even for storms below the maximum threshold for failure to occur,
Washington State Department of Transportation (WSDOT) still closed the floating bridge to traffic. The original bridge carried two lanes of traffic in each direction, but did not include emergency shoulders or pedestrian and bicycle crossings. This posed traffic problems since any obstruction caused by car breakdown, wreck or maintenance would result in traffic backups. In 2011, WSDOT broke ground on the replacement bridge. On April 2, 2016, WSDOT held a grand opening ceremony, allowing the public to explore the top deck of the new bridge on the westbound side. The replacement bridge opened to westbound traffic on April 11, 2016, and opened to eastbound traffic on April 25, 2016. The old bridge was permanently closed at 23:00 PDT on April 22, 2016, with demolition completed by the end of 2016. The bridge was removed by spring 2017.
Construction The cost of all improvements to SR-520 between I-5 and I-405, including the new bridge, is forecast to be $4.65 billion. The first of 21 longitudinal pontoons were positioned on August 11, 2012. Each pontoon is long and wide. The pontoons were constructed in
Aberdeen by
Kiewit Construction. Pontoon construction was plagued by errors and shoddy construction. Reports included workers installing incorrectly sized
rebar, installing it in the wrong location, and even having it missing altogether. Workers also poured concrete in weather that was too wet or too cold. Several of the new pontoons have had problems with cracking, which has been blamed on Kiewit's poor work. An independent auditor stated that there had been a long-running pattern of poor-quality work and that
WSDOT failed to force Kiewit to take corrective actions. An inspector for the construction called it a disaster waiting to happen, adding "I won't drive across that bridge when they have it built." By the end of February 2015, enough of the new bridge was in place to block tall ships that used to pass through a drawspan in the Rosellini Bridge. In early July 2015, the westernmost floating pontoon was moved to make room for the installation of the west end of the bridge; on July 8, 2015, all longitudinal pontoons for the new bridge were in place. ==Tolling==