Bridges exposed to harsh environmental conditions are susceptible to structural degradation. To address this, Underwater Construction Company (UCC), a leader in underwater construction and commercial diving, recently completed a bridge piling encapsulation project in Rockwall, Texas. Utilizing advanced fiberglass wrap technology, UCC reinforced previously inspected bridge piles, ensuring long-term durability and protection.

Project Scope and Execution

The project focused on the SH-66 and IH-35 crossings over Lake Ray Hubbard. UCC was contracted by the Texas Department of Transportation (TXDOT) to perform marine pile restoration using Denso fiberglass-reinforced polymer (FRP) jackets and SeaShield 550 epoxy grout, a high-performance, TXDOT-approved solution. The work included:

  • Full encapsulation of bridge piles from the mudline to the top tier.
  • Work in depths of up to 30 feet.
  • Application of FRP jackets.
  • Epoxy grout application to halt corrosion and fill existing spalling.
  • Adherence to TXDOT regulations and environmental protocols.

Learn more about our expert marine piling repair services.

Overcoming Project Challenges

Variable weather conditions required a strategic approach to scheduling. UCC’s team optimized productivity during favorable weather windows, completing the project four weeks ahead of schedule. Proactive material procurement, particularly for varied FRP jacket sizes, prevented delays. The piling encapsulation project involved both underwater and dry-site execution, with UCC’s dive team utilizing work barges and owned pumping equipment for efficient epoxy grout application. Ratchet straps, placed every four feet, ensured jacket integrity during installation.

The Piling Encapsulation Process

Encapsulation began with thorough surface preparation, removing marine growth and debris to ensure a clean application surface. This step was critical for preventing contaminants from compromising the integrity of the installation. Denso FRP jackets were then installed, secured with ratchet straps. These straps provided additional strength and ensured that the jackets maintained their form throughout the process.

Once secured, the jackets were filled with Denso SeaShield 550 epoxy grout, forming a one-inch protective layer. The grout was carefully pumped to prevent bulging or gaps, providing full encapsulation. Post-application, the grout was cured, creating a durable and long-lasting barrier against further corrosion and structural deterioration. A final inspection confirmed compliance with all project specifications and TXDOT standards.

Regulatory Compliance and Environmental Stewardship

UCC collaborated with a Texas engineering firm to ensure regulatory compliance, managing permitting, traffic postings, and documentation. UCC also implemented stringent environmental precautions, including:

  • Grout containment within encapsulation forms to prevent leakage into the waterway.
  • Strict waste disposal protocols, removing all cleanout materials from the site.
  • Conducting work without disrupting local wildlife or water quality of Lake Ray Hubbard.

Long-Term Benefits and Project Success

The successful completion of the project provides 16-20 years of protection, preventing pile deterioration and ensuring the bridge remains structurally sound. UCC’s efficient project management, including precise material coordination and expert field execution, ensured timely completion and adherence to all requirements.

Leverage Our Piling Encapsulation Expertise

UCC’s expertise in piling encapsulation and marine pile restoration delivers robust solutions for extending the lifespan of critical infrastructure. Our team ensures efficient, safe project completion. Reach out today to discuss your piling encapsulation requirements and discover how we can support your project needs.

About Underwater Construction Corporation

As one of the largest inland commercial diving services companies in the United States, UCC and its staff of over 200 divers, supervisors, and project managers operate from multiple regional locations in Connecticut, Maryland, Michigan, South Carolina, Tennessee, Texas, Wisconsin, and the United Kingdom. Through our global network of offices and associates, UCC has performed projects in over 25 countries. Every job, no matter the size, receives the professionalism customers expect from UCC.

Contact us with your questions about piling encapsulation and let’s talk about how we can help you achieve your goals.