Baltimore Key Bridge rebuild hits $5.2 billion as pier protection drives costs

(UI) — The estimated cost to rebuild Baltimore’s Francis Scott Key Bridge has nearly doubled, driven largely by expanded pier protection systems, deeper foundations, and taller substructures required under updated federal safety standards.

The Maryland Transportation Authority said it has revised the project’s cost range to $4.3 billion to $5.2 billion, with an anticipated return to traffic in late 2030, reflecting design advances and rising construction costs since early estimates were issued in March 2024.

“As design has advanced and pre-construction work progresses, it became clear that material costs for all aspects of the project have increased drastically since the preliminary estimates were prepared less than two weeks after the initial tragedy,” said Acting Transportation Secretary and MDTA Chair Samantha J. Biddle. “The updated cost range and schedule are directly correlated to increased material costs and to a robust pier protection system designed to protect the new Key Bridge and reduce the likelihood of a future ship strike to the bridge’s foundational piers.”

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Pier protection and foundations drive scope increase

Project officials said the rebuild now includes a 1,665-ft main span, larger and taller piers, and a massive pier protection system designed to withstand impacts from modern marine traffic. The protective fender systems alone are larger than a football field and were not included in the initial post-collapse cost estimate, MDTA said.

The taller bridge towers—needed to support a 230-ft deck height—also significantly increase foundation and substructure costs compared to early assumptions.

“These elements are necessary to comply with current American Association of State Highway and Transportation Officials guidelines for new bridges,” MDTA said.

Compressed design timeline, rising construction costs

Preliminary estimates were issued less than two weeks after the March 2024 collapse to support federal emergency funding requests. Since then, MDTA said it has incorporated updated data from advanced design work and pre-construction activities, including negotiations with progressive design-builder Kiewit.

“Typically, a cost estimate would not be provided on a project of this size until much later in the design process,” said MDTA Executive Director Bruce Gartner. “The Key Bridge Rebuild achieved 70% design in 14 months compared to other projects that have averaged seven years, while also progressing construction.”

According to the Federal Highway Administration, highway construction costs have risen approximately 72% over the past five years, contributing to volatility in materials, labor, and contractor pricing nationwide.

Funding and recovery efforts

Federal funding for the rebuild is expected to cover 100% of eligible emergency relief costs under the American Relief Act. Maryland officials said the state is also advancing upfront construction funds and applying insurance proceeds to offset costs.

The state continues to pursue legal action against the owner and manager of the cargo vessel involved in the collapse to recover reconstruction expenses and related damages.

MDTA said design and pre-construction work continues, with groundbreaking expected in the coming months.

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