the removal of a birm from a levee. Part of the Freeport Hurricane Flood Protection Project, a stabilization wall had to be constructed before the project began to ensure its integrity. McCarthy was hired to deliver the Levee Stabiliza - tion project, which called for a 3,800-line foot steel combina - tion wall (combi-wall) that crowned Dow Levee Road. The project was completed in less than three months, finish - ing before the start of hurri- cane season. In 2019, McCarthy was awarded the Velasco Container Terminal Expansion for Port Freeport, Texas, which is the single largest project built by a public port on the Texas Gulf Coast. This 925-foot extension of the current berth is meant to accommodate post-Panamax gantry cranes and includes the construction of Berth 8. The
Beaumont’s Main Street Terminal 1, which will increase the port’s general cargo handling capacity by more than 15 percent. The main dock for the Port of Beaumont, the original structure collapsed in 2012. This means that McCarthy has to first demolish the entire dock–which will be made difficult due to no water visibility. This demolition process is critical as any remaining portions of the dock could hinder pile driving installation. However, despite its challenges, this demolition process provides op - portunity for a complete redesign of the terminal–placing sustainability and resiliency at the forefront. This will come to fruition in the form of key building elements such as concrete piles that provide a corrosion- resistant foundation and a final concrete topping slab to be constructed with synthetic concrete reinforcing fibers. By opting for synthetic con - crete reinforcing fibers rather than traditional welded steel wire mesh, the surface will be corrosion-proof, slowing deterioration. The Main Street Terminal 1 project in Beaumont is scheduled for completion in mid-2024. Another rapidly expanding port along the Texas Gulf Coast is Port Freeport, located 60 miles from downtown Houston. In addition to constructing new facilities and container terminals, Port Freeport is currently also deepening its waterways with the $295 million Free - port Harbor Channel Improvement project. The Harbor Channel Improvement project will deepen the waterway from its previous depth of 46 feet to 56 feet. Before dredging could commence on the Harbor Channel Improvement project, levee stabilization had to be completed. The waterway’s widening and deepening called for
scope of McCarthy’s work on this project includes the demolition of the existing concrete relieving platform, excavation, combi-wall bulkhead, new wharf, wharf piling, dredging, slope protection, fend- ers, electrical, and crane rail installation. Part of this project includes dredging the berth to 56 feet, which matches the depth of the Freeport Harbor Channel Improvement project. There are understandable challenges that come with working on such a large project. It will require approximately 29,200 tons of steel piling, but the challenge is that the piles have extremely tight driving toler- ances. This will require a 20+ foot template to ensure accurate align - ment of the pilings. In addition, slope protection grout mats will be placed between the piles with extreme care being taken to not damage the new piling. The project is scheduled to be completed later this year. The expansion of ports along the Texas Gulf Coast is indicative of a trend in infrastructure investment and expansion. The size and volume of container shipping over the last few years has resulted in an increas- ing number of long term expansion projects throughout the region from both private and public entities. As these projects continue to receive funding and support, companies like McCarthy are poised to serve a critical role in what this infrastructure looks like in the future.
LUKE CAROTHERS is the Editor for Civil + Structural Engineer Media. If you want us to cover your project or want to feature your own article, he can be reached at lcarothers@zweiggroup.com.
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August 2022 csengineermag.com
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