Breakthrough 2025 Edition

Last Wednesday, September 24th, 2025, was a day to celebrate as the HRBT Expansion project marked achievement of a major project milestone. Our beloved Mary the Tunnel Boring Machine was received with excitement and cheers from many of the hardworking men and women who have dedicated years to ensure her safe return to the facility’s South Island. The occasion marked, what will be for many, the highlight of their professional careers as it signified the completion of one the most technically challenging undertakings in Virginia Department of Transportation history.

While Mary’s journey is complete, her legacy will live long beyond her time excavating the tunnels on the project. The void beneath the bay she has left behind will soon be filled with the roadway that will serve as a key thoroughfare in our region for generations to come and support billions of trips across the Hampton Roads harbor.  We cannot be thankful enough for the expertise and dedication of all of those who have supported her through her journey. From the designers and engineers who conceived the idea, to the fabricators and tradespeople who brought her to life, to the men and women responsible for operating her along the journey, job well done!

But…we are not done yet! The second breakthrough was just one major step in our long journey to relieve the region’s most congested roadway. There will be many more reasons to celebrate with the milestones yet to come in 2025. For now, the entire team of more than 2,000 construction professionals are back to work. Remember, the traveling public plays a part, too; put down your phones, focus on the road, and drive safe!

Ryan Banas

Project Director

Mary Makes Landfall on South Island

Mary The Tunnel Boring Machine broke through at HRBT's South Island on Wednesday, September 24, 2025. Mary began her journey to construct the project's twin bored tunnels in April 2023. Twenty-nine months, three miles of tunneling, and 21,420 precast segments later, Mary's journey is complete.

Using the most advanced tunneling technology in the United States, final boring of the twin tunnel at the Hampton Roads Bridge-Tunnel (HRBT) Expansion Project was completed September 24, 2025, at the South Island, making history a second time for the Virginia Department of Transportation (VDOT).

A rush of slurry and water resembling an ocean wave preceded the cutterhead’s arrival as Mary broke through the South Island headwall, completing her latest 11-month mission and beating her previous record by three weeks.

Cheers and applause erupted from the hundreds of skilled workers, VDOT and Hampton Roads Connector Partners (HRCP) staff and dignitaries who battled unusually hot September temperatures to witness Mary cross the finish line. Also capturing the moment in pictures and taking pride in the historic day were three grandchildren and a great-grandchild of NASA pioneer Mary W. Jackson for whom the TBM is named.

Mary began the second bored tunnel on October 17, 2024 and completed her journey after installing 1,188 concrete rings.  As the 46-foot in diameter cutterhead emerges from the tube, an additional six rings will be placed to finish the tunnel.

Next, Mary’s cutterhead will be disassembled from the machine’s shield and her trailing gantries extracted from the newly formed tunnel, allowing crews to continue tunnel interior build out. 

Allan Clark, Slurry Treatment Plant conveyor operator wears his breakthrough pride on his shirtsleeve and hard hat!

Staff look on in awe as Mary’s 46-foot diameter cutterhead slowly advances into view, marking a powerful and unforgettable achievement for the project.

Craft and staff from Hampton Roads Connector Partners (HRCP) proudly represent the project's world-class team and capture views of Mary's arrival.

Guests from Federal Highway Administration, Commonwealth Transportation Board, City of Norfolk, HRTAC, Hampton Roads Transportation Planning Organization, and Hampton Roads Chamber stand with staff to welcome Mary.

Members of the Virginia General Assembly were among guests eager to watch Mary's grand reentrance at HRBT's South Island.

Representatives from the United States Navy, Coast Guard, and Air Force were recognized for their continued partnership throughout the project.

Hampton University was celebrated as a key stakeholder in the success of the HRBT Expansion Project and Hampton Roads Express Lane (HREL) Network.

Sunday, October 5, 2025

12:00 p.m. to 3:00 p.m.

Wednesday, October 22, 2025

10:00 a.m. to 4:00 p.m.

• Meet project staff with years of transportation and engineering experience.
• Learn the history of the HRBT, the first tunnel built between two man-made islands.
• Experience regional history through artifacts discovered during excavation
• Understand how Mary The Tunnel Boring Machine built the new twin tunnels.
• Receive the latest construction updates and impacts from Norfolk to Hampton.
• See timelapse videos and aerial views of current project progress.

Stop by the Welcome Center to receive a special edition publication about Mary The TBM, which includes a timeline of Mary, from evolution through excavation.