Freyssinet USA was chosen as the General Contractor for the structural rehabilitation of two vital bridges connecting Bogue Banks, a barrier island in North Carolina:

  • Bridge #68 on SR-1182 (Atlantic Beach Causeway)
  • Bridge #6 on NC-58 (Emerald Isle Bridge)

Spanning the Intracoastal Waterway, these aging structures required extensive bridge repair to extend their service life and ensure safe access for residents and visitors.

  • Atlantic Beach Bridge: 0.74 miles, 49 spans, four lanes with pedestrian/bicycle access
  • Emerald Isle Bridge: 0.87 miles, 59 spans, two lanes
  • Project Location
    Smyrna, North Carolina
  • General Contractor
    Freyssinet, Inc.
  • Customer/Owner
    North Carolina Department of Transportation (NCDOT)
  • Specialty Subcontractors
    Truesdell; Gemstone; Intercoastal Marine
  • Project Duration
    March 2017-July 2023
NCDOT Atlantic Beach & Emerald Isle Bridge Repair

Freyssinet's Scope of Work

Emerald Isle Pile Jackets

Freyssinet conducted the structural repairs to the bridge superstructure and substructure from the water. The repairs included shotcrete, metalizing, pile encasements, cathodic protection jackets, crack injection, epoxy coating, girder repairs, span repositioning, bearing replacement, bearing resetting, steel cleaning and painting, and Polyester Polymer Concrete (PPC) deck overlay.

A two-bar metal rail was also added to the Emerald Isle Bridge. Lastly, a new FRP fender system was installed at the Atlantic Beach bridge.

Key Success Factors

Freyssinet was managing eleven different subcontractors for this bridge repair project, so clear communication between all parties was a huge priority to ensure the scope was executed smoothly. Especially, since weather conditions were constantly changing and sometimes severe.

The bridge was also surrounded by a unique ecosystem that needed vigilant protection. Freyssinet made sure to comply with all the different environmental restrictions and permits to protect the wetlands, including cleaning up materials and waste acquired from the project and taking necessary precautions to avoid damage to animal habitats.

Additionally, road closures and traffic control were a challenge. Freyssinet conducted most of the work during the offseason to alleviate disruptions, but we still had to install, maintain, and remove all traffic control devices throughout the entire six (6) years of their work to ensure safe and efficient passage of vehicles.

 

Results

Freyssinet was able to tap into their long-standing experience repairing transportation structures and high-level safety practices to effectively complete this project, ensuring NCDOT received the best quality product.

The project was completed safely, efficiently, and in full compliance with environmental and operational standards.

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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Bridge Repair Solutions

When exposed to the environment, increasing traffic loads and hazards, even the most well-designed bridges need repair and protection in order to ensure that their intended design life can be achieved.
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