A Message from Project Leadership
Ryan Banas, Project Director
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The past six weeks have been nothing short of active, productive, and record-setting. While the work Mary, the tunnel boring machine, is performing to construct our two new tunnels is a monstrous engineering feat, the HRBT Expansion Project is so much more than a tunnel. Visible as you drive across the harbor, crews have been pouring multiple permanent bridge decks for the South Trestle near Norfolk. They are also tying in new decks to existing structures at the eastbound spans of the Willoughby Bay Bridge. Each effort represents one of the many critical aspects of ongoing bridge construction across the project. In total, 25 bridges will be replaced, reconstructed, or rehabilitated near live traffic. |
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The project made history on November 19, after crews completed a 31-hour continuous concrete pour that totaled 5,480 cubic yards filling the North Island receiving pit. This feat is the single largest continuous pour of concrete in VDOT history. The undertaking required more than 548 concrete trucks, three pump trucks, and countless hours of meticulous planning, preparation, and execution. This activity was instrumental in continuing activities to ensure the receiving pit is ready for Mary's breakthrough in spring 2024, where she will be received, rotated 180 degrees, and sent on her way back to Norfolk to complete her second bore.
Speaking about Mary, she continues to bore away beneath the Hampton Roads Harbor at a steady pace. Recently, she posted a personal best by mining more than 83 feet in a 24-hour cycle; that's 12 rings in one day! Mary and the many construction staff, engineers, and operators who keep her humming have mined over 3,659 feet and installed more than 543 rings. She is well on her way to finding daylight on North Island, with more than 46% of the 7,940 feet for her first tunnel completed.
We appreciate everyone's continued support and enthusiasm to learn more about the project. We hope you enjoy this edition of the newsletter, and we look forward to sharing our progress and records as we continue to deliver each phase as quickly and efficiently as possible. As we near the end of 2023, we hope you enjoy the many celebrations, gatherings, and welcomed distractions that come along with it. However, we ask that you stay focused on the road when navigating our work zones so our team members can share those same traditions with their families and friends.
Drive Safe,
Ryan Banas
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Construction Advances in Willoughby Spit Area
Upcoming Traffic Shift on 13th View Street in Norfolk
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As tunnel boring continues underwater, Hampton Roads Connector Partners (HRCP) construction crews are making significant headway on bridge work above ground near 13th View Street in Norfolk. While work on the east side progresses, crews are preparing to begin construction on the west side of the road. Since July, traffic on 13th View Street has been reduced to one lane on the west side of the road, and traffic flow under the bridge has been directed by alternating traffic signals on either side.
During the next phase of bridge work, scheduled to begin in mid-December 2023 and continue through February 2024, traffic on 13th View Street will stay restricted to one lane, but traffic will be shifted to the east side of the road while temporary traffic signals remain in place.
Construction will include drainage installation, pavement restoration, and lead abatement efforts on the I-64 bridges over 13th View Street.
In addition to the work underway on and above 13th View Street, groundwork for the new off-ramp from I-64 east to Bayville Street continues. More details on the new configuration and construction timeline for the Bayville Street I-64 east on and off ramps will be in a 2024 edition of the HRBT Expansion Project Magazine.
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Ground-level photo of one lane of alternating traffic on 13th View Street under I-64 bridges. |
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Aerial photo of current construction work on 13th View Street and Bayville Street in Willoughby Spit area of Norfolk. |
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Some say, “out with the old, in with the new,” but the HRBT Expansion Project has a plan to preserve history and build on portions of infrastructure that are still holding strong. Although crews are building three new, permanent marine trestles, their work wouldn’t be complete without repairing, rehabilitating, or replacing auxiliary structures along the corridor. A total of 25 bridges are scheduled for some much-needed rehabilitation. Five will be completely replaced, while the other 20 will be widened and restored to accommodate the interstate’s increased capacity.
Each bridge is a piece of the same puzzle, but one distinguishing factor will set apart the new, the old, and the upgraded. All existing VDOT structures have a unique identification number and a brass plate that helps uniformly identify structures in the field. The original design, pictured below, displays the seal of Virginia and the year the structure was built. These plates will be temporarily removed during rehabilitation and reincorporated into the renewed structure along with a ‘widened’ date plate. As for the brand-new bridges, their original brass plates will be stored prior to demolition and replaced with a 21st-century edition that features the year the structure was erected, its identification number, and the VDOT emblem.
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Aerial view of the North Island (Hampton side) bridge/trestle expansions |
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Bird’s eye view of the North Island receiving pit. When Mary breaks through in early spring, its crews will turn her around to begin the second tunnel towards Norfolk. |
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Take a look at the South Island (Norfolk side) of the HRBT Expansion Project featuring the slurry treatment plant (lower right); wastewater management plant (lower left), and the receiving dock for tunnel segments. |
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An impressive view of the South Island superstructure that will carry eight lanes of traffic, connecting Norfolk to the South Island. |
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Driving Piles. These concrete cylinders (middle) are support structures for the new permanent bridges/trestles that will carry westbound traffic from the North Island to Hampton. |
Bridge widening support structures in place at Bay Avenue, among the 25 bridges within the project corridor that will be replaced, rehabilitated or widened. |
Sky’s the Limit! Metal support structures called abutments at Patrol Road are used to support the bridge by carrying its weight and the weight of vehicles passing over it. |
Three Views on Willoughby Bay Bridge
(Left)the new Willoughby Bay Bridge almost completed, (Center) hydro demo of existing bridge deck (exposed rebar is the red rusty color), (Right) traffic on existing eastbound bridge.
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Crews performing a slipform operation on Willoughby Bay Bridge eastbound span. |
Equipped to Build: Multi-Service Vehicle (MSV),
the real MVP
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The expansion project is one great, big, well-oiled machine powered by a team of energetic individuals and their tools. One of those tools, tasked with carrying the weight of the massive tunnel segments, is the Multi-Service Vehicle, or as tunnel workers call them, MSVs. As the new tunnel stretches towards the peninsula, the project’s three MSVs have become essential to the tunnel boring process. Primarily used to deliver nine 10-ton tunnel segments to Mary at a time, MSVs may also be seen entering or exiting the tunnel with operating equipment and materials, and as boring continues, construction crews are in tow. |
Sporting a maximum capacity of about 220 tons (44,000 pounds) along with space for 21 people in the attachable mantrip car, MSVs significantly reduce the number of trips required to get the job done, saving both time and resources.
They are stronger than fast, with a top speed of only 11 mph. Still, the efficiency and enhanced safety of fewer vehicles in the tunnel make the MSVs worth the wait. MSVs are trackless, allowing for surprising flexibility and range of motion for such a large vehicle. They are built to withstand the rigors of mining. At the same time, they minimize hazards and provide a reliable solution to the tunnel’s complex needs. It’s safe to say that MSVs are in the running for project MVP.
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Outreach: Hampton Roads Built to Thrive |
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Shaping the Future of STEM |
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The HRBT Expansion Project team welcomed fifth graders from Virginia Beach Public Schools to the annual NAS Oceana Air Show Outdoor STEM Laboratory to chat about potential careers, tunnel boring, bridge engineering, artifacts, and local wetlands. |
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Fifth and sixth-grade scholars from Norfolk and Portsmouth Public Schools stopped by the HRBT Expansion Project booth at the Naval Station Norfolk Fleet Fest STEM Day to meet Mary and engage in some “boring” tunnel trivia. |
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Just one stop on the NASA Langley Research Center Open House tour, the project team challenged STEM enthusiasts from far and wide to try their hand at constructing a paper TBM while learning about HRCP employment opportunities and Mary’s state-of-the-art technology. |
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Regional college students and industry professionals studying tunneling, civil geology, and mining gathered for a rare day-in-the-life look around the construction site as part of the Underground Construction Association 'Down for That' Tunneling Field Course. |
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Expanding Entrepreneurship & Economic Development |
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Commissioner Stephen C. Brich joined the HRBT Expansion Project Team to celebrate women in transportation at the WTS Hampton Roads 13th Annual Transportation Reception. |
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The magnitude of the HRBT Expansion Project is remarkable on its own. Yet, the historic and technological feat of construction won't be the only achievement to celebrate when all is said and done. As team members spread the word about construction impacts on drivers and community members, they also took time to broadcast the region's bright future this fall.
In addition to the vast number of ongoing employment opportunities available online and at outreach events like the October Hampton Roads Construction Hiring Expo, improvements to the HRBT are projected to increase the region's overall economic vitality and competitiveness. VDOT Hampton Roads District Engineer Chris Hall and Project Director Ryan Banas joined state transportation leaders at the 2023 Virginia Governor's Transportation Conference this October to discuss this year's theme, Driving Economic Opportunity and Connecting Communities. The HRBT Expansion Project is doing just that.
Not to mention, it's leading the region in bridging the opportunity gap in the transportation industry. Earlier this month, the Project Team accepted the WTS Hampton Roads 2023 Innovative Transportation Solutions Award for their creative approach to relieving congestion while prioritizing women in leadership and awarding more than $500 million to Disadvantaged Business Enterprises (DBEs) and Small, Women and Minority-owned (SWaM) businesses to date. Leadership also had a chance to express this commitment to entrepreneurs one-on-one at Black Brand's Black Diamond Weekend, an annual business development conference.
As construction in the corridor progresses, opportunities for individuals and entrepreneurs will continue to emerge. Get involved and visit HRCP Jobs to learn more about current job listings and contract opportunities for the HRBT Expansion Project. Also, learn about VDOT's Small Business Enterprise Program (VSBEP), designed to maximize DBE and SWaM business opportunities to participate in other federally-assisted projects.
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HRBT Expansion Podcast | November 2023 |
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A look at the bigger picture |
HRBT Tunnel Talk, “A Boring Podcast” returns with another episode to keep you in the loop of all the project happenings.
Available for free on the project website, Apple, or Spotify, hear this month’s guests, VDOT Hampton Road District’s Nina Ullrich and the City of Hampton’s Robin McCormick, share how drivers can get through traffic while supporting local economies and infrastructure.
Tune in during your next commute for a local perspective on the importance of working across localities to improve regional transportation plus a snapshot of how it all connects to the Hampton Roads Express Lanes Network (HRELN).
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Didn’t catch last month? Click here to see what you missed.
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Hampton Roads is home to 15 military installations, one of the world’s largest populations of active-duty military personnel, and more than 200,000 veterans. So naturally, we here at the HRBT Expansion Project have a special affinity for our nation’s service members as many of our own staff, their families, and friends have previously or are still currently serving our country. We recognize the importance of their missions and want to minimize disruptions to the military movements that happen each year within the region.
Our appreciation is even reflected into the project’s design. Through tunnel boring technology and detailed engineering, crews are paving a way for enhanced regional connectivity all while keeping waterways clear for marine traffic and daily military activities.
It's an honor and privilege to support national safety through innovative infrastructure, but what makes us even more proud are the veterans who now dedicate their time and talents to the mission of improving the transportation network for Hampton Roads’ residents, visitors, service men and women alike. The veterans on our team are one of a kind, bringing a wealth of knowledge, unwavering commitment to teamwork, efficiency of performance and problem solving, and an indisputable standard of excellence that can only be cultivated by years of training and service.
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For the Love of Construction |
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Walter Watts,
RS&H Construction Field Engineer, VDOT Team
Most people can't say they grew up to be what they thought they'd be. Some find new interests or gifts to pursue along their career journey or decide to save their dream-chasing days for retirement. Walter Watts, VDOT's Construction Field Engineer and on-site problem-solver at Willoughby Spit, has a different story.
It's been a long road to his current role on the HRBT Expansion Project, where he ensures compliance with safety, environmental, and quality construction requirements. Though he stumbled into engineering, his love for construction and commitment to mastering the art since his teenage years make him an asset to the team. He was initially inspired to work in the field by his father's construction company, which led Walter, a Virginia native, to study civil engineering at Virginia Tech over a decade ago. Keeping with his goal to continue the family legacy, he focused his coursework on construction, graduated in 2010, and accepted his first job at one of North America's largest construction and engineering organizations. Read more...
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Get In the Know, and Then Go! |
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Sign Up To Receive Updates! |
Sign up for the HRBT Expansion Project Alerts to get weekly updates on traffic and construction impacts. Perfect way to “know before you go!”
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The HRBT Expansion Project team is committed to staying connected with the region for the life of the project. Like, join, follow, or tweet about the project on our social media channels. |
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