As lead designer as part of the design-build team, we performed field inspections of PANYNJ’s four critical hubs and provided design for associated repairs to meet a 100-year service life. Our team performed a variety of tests to locate and quantify voids hidden behind steel blast plates. First, we deployed ultrasonic testing, extraction of plate samples, and load-testing of the existing stud-anchors to verify the adequacy of the existing plates. The second test was acoustic testing. If concrete is tapped with a hammer and a hollow sound is emitted, the concrete is delaminated and likely needs repair. This same concept was implemented to locate void regions behind the steel blast plates. The inspection teams used a wheeled tool to quickly sound larger areas in tandem with standard hammers for localized areas. Finally, we used infrared testing to validate the acoustic testing. Repairs included sealing cracks greater than or equal to 0.012 inches and voids with epoxy, installing new resinous floor coatings, and painting surfaces damaged by saltwater.

Planning was vital to mitigate impacts for pedestrians and workers. Work occurred in heavily trafficked zones, including an active below-grade roadway network used for daily operations. Construction was phased to alleviate impacts on workers and pedestrians, including lane closures and night or weekend work.

Through collaboration with the design-build team, third parties, and the client, the project was completed on schedule and under budget. The repairs met the goal of a 100-year, water-resilient service life.