Freyssinet’s scope of work for the Wallops Island Bridge entailed repairing the substructure’s pier caps, girders, diaphragms, abutments, and columns with multiple methods of concrete repair and strengthening, including epoxy injection. To safely proceed with the repairs of pedestals and pier caps, temporary shoring of the existing structure by jacking and blocking was necessary. The girders were inspected, concrete was repaired as needed, concrete surfaces were abrasive sandblasted, and prepared for installation of Fiber Reinforced Polymer composites. The specified girders showing signs of distress or pre-stress strand loss due to corrosion were wrapped with FOREVA® TFG-600 (Glass Fiber Reinforced Polymer), strengthened with FOREVA® TFC-1100 (Carbon Fiber Reinforced Polymer), and covered with a UV coating to protect them from the elements and ensure longevity.

Concrete repairs and expansion joint replacements also took place prior to repairing the riding surface and underside of the bridge deck. The deck was then sealed and striped to deliver a quality product. To access repairs that were difficult to reach, suspended work platforms were hung on the structure by utilizing large hydra platforms. Anchoring and setting the platforms on such an important bridge was difficult due to utilities and obstructions that were critical to supporting the launch range, but Freyssinet was able to work closely with NASA to get the bridge access platforms installed safely and securely.

Key Factors to Making Our Repairs a Success

• The project was split into several phases due to the length of the Wallops Island Bridge and changing weather conditions such as tropical storms, high winds, and floods. Daily weather meetings were held, which ensured the project was completed safely and on time. Cold temperatures during winter also posed schedule concerns, but Freyssinet was able to provide stable working conditions by creating a temporary enclosure outfitted with heaters, ducts, and blankets that helped alleviate ambient conditions and allowing the work to progress.
• Freyssinet also set up a highly effective containment system to ensure that all debris, equipment, and material never impeded the surrounding wetland habitat. Dustless equipment was utilized to
  perform tasks, while debris netting and lumber were used to set impervious containment to protect the ecosystem’s unique wildlife.
• COVID-19 played a significant role, as the crew had to deal with new safety measures like masking, vaccinations, social distancing, and more during the entire duration of work. Freyssinet was able to work through these obstacles and complete the project with no major shutdowns or COVID-19-related infections.
• Freyssinet’s project management team was able to resolve material and equipment shortages by using the company’s global reach to source FRP/CFRP from Italy and epoxy resin from France.
• Communication was a key factor due to NASA’s strict security concerns. All communication had to be monitored, and only certain radio channels could be utilized. The bridge’s design also created multiple blind spots that established a necessity for daily traffic control and consistent communication.