Inside the Disaster at the Francis Scott Key Bridge

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Introduction
On March 26, 2024, Baltimore faced a significant tragedy when a massive container vessel struck the 1.6-mile-long Francis Scott Key Bridge, resulting in the death of six construction workers. This catastrophic event not only had immediate human and economic repercussions but also prompted swift action from Baltimore for cleanup and the design of a new bridge. This comprehensive examination delves into the details of the accident and the colossal effort involved in creating a new mega bridge.

The Francis Scott Key Bridge
The Francis Scott Key Bridge, operated by the Maryland Transportation Authority (MDTA), has been a critical infrastructure piece since its opening in 1977. The bridge spanned 9,000 feet, constructed from steel and concrete, featuring a continuous steel through-truss section over the Patapsco River. The main span provided 185 feet of vertical navigation clearance and about 1,100 feet of horizontal clearance between supporting piers. By 2023, it handled an average daily traffic of 34,000 vehicles, with 10% being trucks.

Protection for the bridge included four large dolphins constructed with 25-foot diameter sheet piles filled with concrete, crucial for both impact protection and navigational assistance.

The Accident
The cargo vessel Dali, powered by a 55,000-hp diesel engine, experienced a catastrophic failure when two electrical circuit breakers tripped, causing a blackout. This led to the vessel losing both propulsion and steering while it was on a collision course with the Key Bridge. Despite efforts to manually restore power and drop the anchor, the Dali struck pier no. 17 at 6.5 knots, causing six spans of the bridge to collapse onto the vessel.

The accident resulted in the deaths of six construction workers and disrupted maritime access, affecting nearly 70 ships. The cleanup required a significant effort from the U.S. Army Corps of Engineers (USACE), the U.S. Navy, and other specialists, involving a substantial fleet of cranes, tugboats, and salvage vessels.

Cleanup and Effects
The bridge collapse had immediate and far-reaching effects. Maryland's Governor declared a state of emergency, and the Maryland Secretary of Transportation suspended all shipping to and from the Port of Baltimore. The cleanup operation led by USACE involved over 1,100 engineering specialists and various heavy-lift equipment.

Debris removal began on March 30, and by mid-April, significant progress had been made, with 3,000 tons of debris cleared and a temporary channel opened for recovery vessels. The salvage team also worked on removing containers from the Dali, and by May 20, the vessel was freed from the wreckage.

The collapse caused significant supply chain disruptions, particularly affecting automakers and major shipping lines. Economists estimated the weekly cost of disruptions at around $1.7 billion, with insurance losses ranging between $1 billion and $4 billion. Baltimore's city officials pursued legal action against the involved shipping companies for negligence.

The Future
In response to the urgent need for a new bridge, the MDTA is expediting the construction process by allowing contractors to bid with their own design ideas. Over 1,700 contracting firms attended a briefing, and a request for proposals was issued, seeking a visually attractive design with minimal piers in the Patapsco River and substantial vessel collision protection. The project aims to complete the new bridge by fall 2028, with significant federal funding expected to ease the financial burden on the region.

The most practical design for the new bridge is anticipated to be a cable-stayed bridge, similar to the Gordie Howe Bridge being constructed on the Detroit-Windsor Border. This design offers strength and faster construction for a bridge of this length. Webuild, an engineering firm, submitted a cable-stayed design proposal resembling Florida’s Sunshine Skyway Bridge.

Regardless of which firm wins the construction bid, the new bridge will be a remarkable mega project, symbolizing resilience and progress in the face of tragedy.
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