Dominion Terminal Associates Project: Concrete Restoration and Corrosion Protection

Recognizing the importance of maintaining its integrity and upon the detection of early signs of structural deterioration, Dominion Terminal Associates (DTA) engaged Freyssinet as the General Contractor in the spring of 2021. Freyssinet’s mandate involved executing comprehensive concrete restoration and implementing protective measures against corrosion, notably through the application of impressed cathodic protection.

DTA is a prominent infrastructure asset comprised of a 1,144-foot-long pier that is situated along the eastern seaboard of the United States in Newport News, Virginia. Established in the mid-1980s, this facility serves as a vital coal export terminal and ground storage facility within the bustling port of Hampton Roads, located on the East Bank of the James River.

General Contractor

Freyssinet, Inc.
Customer/Owner

Dominion Terminal Associates
Engineer

Tam Consultants, Inc.
Specialty Subcontractor

Durability, Inc.
Project Duration

April 2021 - June 2024
Location

Newport News, Virginia

Dominion Terminal Associates

Freyssinet’s Role and Responsibilities

DTA - Freyssinet Conducts Structural Repairs

Freyssinet was in charge of the comprehensive pier rehabilitation, supplying all necessary equipment, labor, materials, and supervision. The project’s scope entailed the removal and replacement of deteriorated concrete within the pier structure supporting the movable coal ship loader and the turning dolphin (primarily used to position vessels in storm or windy conditions).

By the time the project was completed, Freyssinet had completed concrete repair and restoration across 28,200 SF at the DTA Piers.

Corrosion Protection and Structural Enhancements

Freyssinet designed and installed an advanced Impressed Current Cathodic Protection (ICCP) system installation intended to safeguard the existing structure against corrosion and prolong its operational lifespan. DTA opted to adopt the ICCP system in place of the original TSA system (Spray Applied Aluminum Coating). The system is complimented by a bulk zinc anode network protecting the 106 piles supporting the superstructure.

Beyond these measures, the project also encompassed an array of supplementary repairs, including addressing girders, cross beams, pile caps, crack repairs at concrete piles, and 40,345 linear feet of new steel reinforcement.

Dominion Terminal Associates in Newport News, Virginia - Freyssinet Team Conducting Corrosion Protection

Long-Term Maintenance and Inspection

Freyssinet would be conducting annual inspections on the Cathodic Protection (CP) system to ensure ongoing efficacy and compliance with regulatory standards for a 14-year period. This comprehensive approach underscores Freyssinet’s commitment to delivering holistic solutions to fortify critical infrastructure assets for sustained performance and longevity.

Key Success Factors: Workforce and Innovation

Several aspects of Freyssinet’s approach and execution of the project were key factors for success. These factors encompassed an adaptable workforce capable of navigating highly variable weather conditions and the regular traffic of large vessels. The crew’s exceptional adaptability, concentration, and expertise were crucial in ensuring continuous progress amidst these challenging environmental elements.

Freyssinet also provided innovative methods, particularly in overcoming the lack of boat/barge access during high tide and within sections of the pier. Through the strategic utilization of work floats and suspended platforms, they demonstrated their ability to devise creative solutions to access and work on the structure’s difficult to access areas efficiently.

Planning, Safety, and Environmental Compliance

In addition, Freyssinet highlighted the importance of meticulous project planning and the implementation of strict safety measures. This commitment ensured both operational efficiency and the safety of the workforce, effectively addressing the unique challenges posed by the project environment.

Environmental compliance stood out as another key aspect of Freyssinet’s approach. Their adherence to regulatory standards, including compliance with the Virginia Department of Environmental Quality (VADEQ) standards, was noteworthy. By capturing the demoed concrete on work floats, Freyssinet exhibited a proactive stance towards mitigating environmental impact and safeguarding surrounding wildlife habitats.

Conclusion: A Comprehensive Infrastructure Solution

Overall, Freyssinet’s ability to adapt, innovate, prioritize safety, and comply with regulatory standards under demanding circumstances significantly contributed to the project’s successful completion.

Corrosion Protection

We provide proven corrosion protection solutions to help preserve the performance and safety of concrete structures exposed to harsh marine, underground, or atmospheric environments by preventing or controlling steel reinforcement corrosion.

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Corrosion Protection

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