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Mosaic Big Bend Cellular Berth Repairs & Rehabilitation

Our team managed the rehabilitation of a 37-year-old seawall, addressing issues like corrosion, sheet pile damage, and inadequate fendering. Design solutions included an encapsulation cap, new fendering, and integrating berth mooring systems, ensuring longevity. A site investigation determined the seawall's suitability for deepening the berth zone, guiding geotechnical testing, construction documentation, and ongoing services.

PROJECT HIGHLIGHTS

  • Engineer of Record and project manager for seawall rehabilitation
  • 1,540LF gravity-type Cellular coffer seawall
  • Deficiencies: holes, voids, cavities, corrosion in splash zone, knuckle separations, damaged cathodic anodes; inadequate fendering causing further damage
  • Structural integrity issue with a section not penetrating soil mudline
  • Site investigation to assess seawall suitability for deepening berth zone
  • Deepening from EL -36ft MLW to EL -43ft MLW
  • Design activities: encapsulation cap, supporting cap piles, new fendering, berth mooring system integration
  • Geotechnical soil testing investigation
  • Preparation of final construction documents
  • Construction services provided

Comprehensive Design Activities

As the Engineer of Record and project manager, our team spearheaded the rehabilitation effort for a 37-year-old seawall, overseeing permitting and engineering design. The 1,540LF gravity-type Cellular coffer seawall faced significant deficiencies, including holes, voids, cavities, extensive corrosion, knuckle separations, damaged cathodic anodes, and an inadequate fendering system causing distortion. A structural integrity issue arose, with a section not penetrating the soil mudline. A site investigation evaluated the seawall's ability to withstand deepening the berth zone from EL -36ft MLW to EL -43ft MLW.

Design activities were comprehensive, involving the creation of an encapsulation cap recessed within the curved tops of the existing cell structure. Supporting cap piles were introduced to prevent further corrosion of exposed above-water steel sheet piles. Additionally, a new fendering system was designed, and integration with the existing berth mooring systems was addressed. A geotechnical soil testing investigation informed the project, leading to the preparation of final construction documents. The Engineer of Record and the project team provided construction services to implement the rehabilitation plan successfully.