The Channel Five Bridge is one of the precast segmental concrete bridges on SR-5 along the Florida Keys, providing a safe and efficient transportation route between Lower Matecumbe and Craig Key. This high-level crossing ensures uninterrupted travel for residents, visitors, and commercial vehicles, helping sustain daily life and economic activity throughout the community. The bridge also supports the region’s tourism-driven economy by maintaining seamless access to local businesses, attractions, and services. In addition to its role on land, the Channel 5 Bridge benefits marine traffic by allowing boats to pass safely beneath its span, preserving the area’s vibrant recreational and commercial boating activity.

Freyssinet is proud to contribute to the long-term performance of this essential structure as the main contractor on the bridge’s repair work. Our work focused on restoring and protecting key components of the bridge to ensure its long-term performance and safety for the community.

  • Main Contractor
    Freyssinet, Inc.
  • Location
    Florida Keys, Florida
  • Project Duration
    2022-Ongoing

Column and Pier Shaft Repairs

Freyssinet repairs on channel five bridge: Zinc anodes inside the concrete to protect the rebar and applying a Thermal Spray Aluminum (TSA) coating

Freyssinet successfully repaired over 1,290 cubic feet of concrete across multiple columns, overcoming significant challenges such as limited access over water and strict sequencing requirements to preserve the bridge’s structural integrity. Our team adapted to changing weather conditions and used custom scaffolding solutions to maintain safety and efficiency.

Pier shaft repairs were completed using a submerged steel platform designed in-house, allowing our crews to work safely while partially immersed. This innovative setup provided full access around each shaft, reducing downtime and improving productivity.

In total, Freyssinet addressed approximately 1,000 cubic feet of repairs across 128 shafts on the Channel Five Bridge, ensuring each section met our high standards for durability.

Other Repair Work on The Channel Five Bridge

Precision Concrete Catching and Underwater Demolition

To prevent debris from entering the marine environment, we developed custom catching plates to capture concrete during repairs. Underwater demolition was carefully managed with adapted procedures to account for wave action and visibility, ensuring safe use of pneumatic tools and minimizing environmental impact.

Footer Repairs and TSA Application

Footer repairs and thermal spray aluminum (TSA) coating were completed under tight weather constraints. Despite working in marine conditions, our team met all deadlines and applied TSA with precision to protect the structure from corrosion and extend its service life.

Jacking Operations and Bearing Pad Replacement

We performed jacking operations on 22 piers to adjust or replace damaged bearing pads using a turnkey solution developed by Freyssinet—including flat jacks, Freyssimat hydraulic jacks, and Hebetec pumps. For four piers requiring heavy shoring towers, we deployed exceptional erection methods to ensure stability and safety.

Nighttime MOT Coordination

To minimize disruption on US-1, all jacking operations were conducted at night with a full maintenance of traffic (MOT) plan in place. This allowed us to complete the work efficiently while maintaining public access on this critical route.

CP Jacket Installation for Long-Term Protection

Following pier shaft repairs, we installed 128 cathodic protection (CP) jackets to safeguard the bridge’s reinforcement steel. These jackets are designed to extend the life of the Channel Five Bridge by up to 40 years, ensuring continued service to the Florida Keys community.

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.
Discover Our Solutions

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.
Learn More

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.
Discover Our Solutions

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.
Learn More

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