10,000 Tons Of Concrete From Collapsed Key Bridge Removed From River As Rebuild Advances

BALTIMORE — Crews have lifted and hauled away about 10,000 tons of concrete that once formed the Francis Scott Key Bridge’s road deck, a visible milestone in Baltimore’s reconstruction effort nearly 19 months after the span collapsed into the Patapsco River.

The update came Monday, Oct. 20, 2025, from the Key Bridge Rebuild program, the Maryland Transportation Authority (MDTA) project team. “All of the concrete that made up the bridge deck has been removed and is now stockpiled on-site, waiting to be recycled,” the program said, noting that some of the material will be reused during construction “to increase sustainability and efficiency.”

Project officials said the next six test piles have been loaded on a barge off-site and are headed to the work zone, part of a 12-pile test program that will inform the final bridge design. Static load testing is slated to begin in the coming weeks “to evaluate the strength and performance” of the foundation system.

(Photo credit – Key Bridge Rebuild/MDTA)

Test pile specs and timing: MDTA said the Test Pile Program was expected to begin on or about Sept. 27, weather permitting. The first six test piles arrived in Baltimore by barge; each is 8 feet in diameter and more than 220 feet long, fabricated with American-made steel. The 12-pile program is expected to run six to eight weeks, with two piles driven per week.

“The Test Pile Program marks another major milestone in the Key Bridge Rebuild project,” MDTA Executive Director Bruce Gartner said, adding that some test piles may be incorporated into the permanent foundations of the new span.

How the testing works: Crews will lift piles into position with a crane and tripping barge, stabilize them in a template with a vibratory hammer, then drive them into the riverbed with a hydraulic hammer. A load frame will apply vertical and horizontal forces while instruments on the piles and equipment feed data to validate the bridge’s design models, according to MDTA.

Community impacts: Over the six-to-eight-week program, two piles per week will be driven, with about two hours of hammering per pile, a sound MDTA likens to a “large bell” at a distance. Work will typically occur Monday through Saturday during daylight hours within a 12-hour window. MDTA has deployed noise and vibration monitors around the corridor and collected baseline readings to ensure activity stays within acceptable limits.

The deck-removal progress comes as Maryland continues demolition and early-phase work under a progressive design–build contract led by Kiewit Infrastructure Co. State planners are targeting a fall 2028 opening for the new I-695 crossing.

What’s next: After test piling and static load testing, crews plan to transition to production piling, then foundation and pier construction. Superstructure work — including steel placement and deck pours — will follow, officials said.

Background: The bridge collapsed on March 26, 2024, after a container ship struck a support pier, killing six roadwork crew members and severing a major freight and commuter link. The Port of Baltimore’s main channel was later restored to full dimensions, and the National Transportation Safety Board’s final report remains pending. State briefings say the rebuild is backed by a mix of federal emergency relief, insurance recoveries and state transportation funds. MDTA also urged boaters to observe ongoing Patapsco River safety zones and guidance during testing and construction.