Emergency Bridge Repair Protects Critical Rail Link at Doza Creek 

On August 5th, during a routine drive past a previous bridge culvert project, the Kaskaskia Regional Port District (KRPD) discovered an urgent issue: the 33-foot-wide Multi-Plate Super Span corrugated metal arch culvert over Doza Creek, installed 48 years ago, was showing signs of imminent failure.

The structure supports a rail bridge that KRPD reconstructed just six years ago — a bridge that plays a vital role in the daily delivery of limestone to the Prairie State Energy Campus. This limestone is used in the plant’s scrubbers to meet clean air quality standards required for operation. The same rail line also carries outbound shipments of gypsum and fly ash, all transloaded through KRPD Terminal #1.

Recognizing the potential impact of a collapse, KRPD’s General Manager immediately contacted the Port’s engineering partner, Volkert, Inc., to assess the situation.

By August 11, Volkert engineers confirmed that the culvert was on the verge of total failure and could compromise the bridge structure above. An emergency KRPD Board meeting was convened, and the Board voted to waive standard contracting procedures to allow immediate corrective action.

The timing was especially critical. The rail line was temporarily idle due to a 60-day maintenance outage at the Jerry F. Costello Lock and Dam, creating a short window to complete the repairs before rail operations resumed. However, nearly half of that window — 27 days — had already passed by the time emergency authorization was granted.

The emergency plan called for installing a sheet pile soil retention system to shore up the soil under the existing abutments, temporarily removing the 60-foot dual I-beam steel bridge, installing bracing for the soil retention system, and then reinstalling the bridge once the structure was secured.

Because the scope of work for the bridge and culvert was part of a federally supported project, the Port needed emergency approvals from both the U.S. Maritime Administration (MARAD) and the U.S. Army Corps of Engineers (USACE) Regulatory Division.

In a situation where every day mattered, both agencies responded with exceptional urgency, professionalism, and a strong spirit of partnership. They moved quickly and collaboratively to recognize the critical nature of the repair and the narrow window available to complete the work. Their swift review and decisive coordination helped KRPD and its partners proceed without delay, ultimately protecting critical infrastructure and ensuring this vital rail corridor remained operational for regional industry and commerce.

As work on the Lock and Dam progressed ahead of schedule, the timeline grew even tighter. The Port needed a contractor capable of mobilizing immediately — and Korte & Luitjohan Contractors, Inc. (K&L) agreed to assist on very short notice at a time when local contractors were already fully scheduled.

K&L mobilized on September 13, removed the bridge on September 15, and by noon that day began driving sheet piles. The team overcame several on-site challenges, including the need for a larger vibratory hammer and added structural reinforcements.

Despite these hurdles, the bridge was successfully reinstalled on September 21 — the same day the Lock and Dam resumed operations — nine days ahead of schedule. Rail operations resumed the following day without any unscheduled delay to customers.

K&L noted that the project required engineers to “design on the fly as site conditions dictated.” Fortunately, the team was able to quickly procure the material, sheet pile, and equipment needed. A spokesperson for K&L praised the onsite crew for making the difference in completing the project by the deadline, stating, “This reflects on our ability to execute and adjust as project circumstances changed from initial phone call to completion.”

The project stands as a remarkable example of teamwork and responsiveness. Thanks to the cooperation of KRPD, Volkert, Korte & Luitjohan, MARAD, and the U.S. Army Corps of Engineers, a potentially catastrophic failure was prevented — ensuring the continued flow of essential commodities to Prairie State Energy Campus and supporting the movement of regional commerce through KRPD’s system.