December 10, 2025
Design, Repair, Strengthen: A Collaborative Bridge Success
When a Bid-Build Project Delivers CM/GC Results
Article by Zeb Hutchison, Superintendent
Coastal railroad bridges often go unnoticed, quietly enduring weather and heavy train traffic. When a century-old span over the San Luis Rey River in Oceanside, California, showed significant corrosion, action was critical to keep one of the nation’s busiest intercity rail corridors operating safely.
Although the project was a traditional low-bid, bid-build contract, our approach reflected principles more akin to a construction manager/general contractor delivery. Early engagement, creative problem solving, and integrated collaboration with the designer and agency turned this conventional project into a hands-on success.
Here’s the story on how this team completed the work ahead of schedule, added value without extra cost, and demonstrated the power of collaboration.
Facing a Century of Coastal Challenges
The century-old bridge stretches approximately 700 feet across the San Luis Rey River, with four spans constructed in 1916 and three in 1925. Exposed to the corrosive coastal environment and supporting 66 daily trains, including commuter, intercity, and freight, the bridge’s critical bracing members, bearings, and gusset plates required careful evaluation.
I remember how challenging it was to plan for work over tidal waters and a multi-use bike path. Some members could not be fully assessed until partially disassembled, making early collaboration with the bridge engineer essential.
Success depended on working together before the first steel member was replaced.
Collaboration Before Contract
Even before a formal contract, we conducted extensive field investigations, strategy discussions, and design collaboration. Working side by side with the designer, we developed alternate design concepts, tested constructible solutions, and created detailed as-builts to support those ideas.
These early efforts were pivotal. They allowed us to develop a new bearing clip concept, identify a path to finish the project four months early, and incorporate an additional $250,000 of work without extra cost—all while maintaining strong profit margins.
Seeing those early conversations translate into real construction outcomes reinforced my belief in the value of proactive collaboration.
Integrated Engineering and Adaptive Planning
Rather than performing exhaustive member inspections, we used targeted field measurements and extensive discussions with the engineer to determine which members truly needed replacement. Bearings, struts, and gusset plates were fabricated to precise specifications, with final dimensions confirmed on-site.
We developed access strategies with the design team, creating temporary platforms that balanced live train traffic, environmental restrictions, and public safety. Incorporating alternative design concepts as the project evolved demonstrated how flexibility can unlock efficiencies that would otherwise be impossible in a conventional bid-build project.
Adding or deducting scope without formal change orders showed me firsthand that collaborative planning produces tangible value without increasing cost. Being part of that integrated approach, blurring traditional roles of design, construction, and inspection helped me see how a shared focus on the project leads to better outcomes.
Real-Time Problem Solving
Unexpected field conditions, like oversized rivets or members requiring immediate attention, were addressed through on-the-spot collaboration. I observed the team adapt quickly, fabricating custom T-bars and bearing clips and adjusting installation sequences to maintain schedule and budget.
Being in the field and part of those decisions allowed me to see how months of pre-contract collaboration, combined with continuous communication with the agency, enabled the project to move forward smoothly despite challenges.
Hands-on involvement and proactive problem solving are critical for success.
Lessons in Collaboration
Looking back on Bridge 225.4, I can clearly see the lessons it offers.
Early and ongoing engagement, flexibility in design and execution, and a focus on owner success are the factors that made this project stand out.
I remember how the pre-contract strategy discussions shaped the alternative design concepts that ultimately made the project more constructible and cost-effective. Watching the team incorporate $250,000 of additional work without extra cost, and finish four months early, reinforced my belief in the value of collaboration. Collaboration is the factor that determines a project’s path and outcome.
Even under conventional bid-build contracts, teams that embrace collaboration and adaptive thinking can achieve results usually associated with alternative delivery models.
Targeted field evaluations allowed us to avoid full member inspections while staying within budget and maintaining quality and safety. Small adjustments and shared problem-solving add up to big wins. By exploring ideas early, building relationships, and addressing hurdles proactively, we turned a routine bridge repair into a model of integrated, project-first delivery.
