Deep Corrugated Steel Arch Provides Minimal Disruption on New Mexico State Highway

Heavy Haul Highway Crossing: A Bridge to Efficiency for El Segundo Coal Mine

Transporting heavy mining equipment across a state highway presents a unique set of challenges, demanding a solution that is both robust and minimally disruptive to traffic flow. When the El Segundo Coal Company, a subsidiary of Peabody Energy, needed to move their massive machinery across New Mexico’s State Highway 509 to access a new coal seam near Milan, NM, they turned to an innovative solution: a deep corrugated steel arch. This case study explores how the El Segundo Coal Company, in partnership with Big R Bridge and Bohannan-Huston, Inc., successfully implemented a deep corrugated steel arch crossing to meet the stringent demands of heavy haul highway crossings while adhering to state highway construction standards.

Overcoming the Highway Hurdle

The El Segundo Coal Company faced the daunting task of moving their heavy mining equipment, including a 2.688 million pound mine shovel, across State Highway 509 without compromising the road’s integrity or disrupting traffic. Moreover, the project had to comply with the stringent standards of state highway construction. To address these challenges, the team selected a deep corrugated steel arch for its inherent strength, rapid installation, and minimal impact on the existing highway. This above-grade crossing provided a clear span, ensuring uninterrupted traffic flow during construction and beyond.

The Super-Cor Solution

Big R Bridge, working closely with the mine and their consultant, Bohannan-Huston, Inc., determined that Big R’s Super-Cor deep corrugated steel arch was the optimal solution for this heavy haul highway crossing. Super-Cor’s reputation for handling the world’s heaviest mining loads, coupled with its cost-effectiveness, made it the ideal choice. The 47-foot span, 23-foot rise, and 130-foot length of the arch provided ample capacity for the frequent heavy haul truck traffic and the massive 2.688 million pound mine shovel.

Swift and Sturdy Construction

To further enhance the project’s efficiency and cost-effectiveness, mechanically stabilized earth retaining walls were chosen as headwalls around the arch. These walls offered both value and speed of installation, contributing to the project’s overall success. Remarkably, the entire crossing, from the initial planning stages to the final installation, was completed in approximately two months, minimizing any disruption to traffic and allowing the El Segundo Coal Company to swiftly access the new coal seam.

A Triumph in Heavy Haul Highway Crossing

The El Segundo Coal Company’s heavy haul highway crossing stands as a testament to the power of innovative engineering and collaborative project management. By utilizing Big R’s Super-Cor deep corrugated steel arch and strategically employing mechanically stabilized earth retaining walls, the project successfully navigated the challenges of crossing a state highway with heavy mining equipment. Moreover, the project adhered to the stringent standards of state highway construction while ensuring minimal disruption to traffic flow. This successful endeavor underscores the importance of selecting the right materials and design for heavy haul highway crossings, ultimately leading to increased efficiency and productivity for mining operations.