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Bridge & Roadway

By applying unique solutions to increase the safety and longevity of our environment.

Tunnel Adit Fill

The Job

This tunnel adit fill project is part of the Purple Line project outside of Washington, DC. Specifically, the adit is located at the pedestrian connection between the Purple Line project and WMATA’s Bethesda station on the Red Line.

The Challenge

Plans call to connect the Purple Line to the Red Line using an adit constructed during the original construction of the Red Line. The adit is approximately 30 feet wide by a 35 foot tall arch. During preparation to blast from a shaft dropped adjacent to the station, a fault was identified passing through the adit.

The construction and design teams were concerned about stability of the adit during blasting operations as the Purple Line access tunnel was excavated towards it. The team determined that filling the adit to plug and stabilize it during blasting would be the most risk appropriate move.

Filling the adit would fulfill the design challenge of stabilizing the rock during blasting. However, it created the following challenges:

  • the tunnel adit fill material would need to be removed after blasting was completed
  • the adit is approximately 100 feet below grade
  • there is very limited space up top
  • material couldn’t segregate, and had to be pumped approximately 250 feet in addition to the 100 foot drop

The Solution

The tunnel engineer of record recommended CJGeo to the contractor. The EOR is familiar with CJGeo’s cellular concrete generation and placement expertise, and thought that cellular concrete would be the lowest risk way to fill the adit, while facilitating excavation and removal afterwards.

CJGeo took five days onsite to fill the adit, in lifts up to eight vertical feet. Due to the potential dead load from the rock cover, 400psi CJFill-Standard was the material of choice. By using our colloidal mixing dry batch process, the material set off quickly, ensuring that it would not consolidate during cure as lower energy mixing methods can suffer from.

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Facing a similar challenge to this tunnel adit fill project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Maryland Concrete Lifting

The Job

This Maryland concrete lifting project is located in Frederick, Maryland. The project is for the MARC system, on tracks also used by CSX.

The Challenge

MARC’s Brunswick Line includes a spur to Frederick, which utilizes a freight track that also serves multiple industrial sites, including quarries and concrete plants. As it winds through an industrial area towards the Frederick station, the line crosses multiple arterial roadways. As Frederick grows, traffic is increasing significantly with both cars and industrial truck traffic.

At two crossings, bellies have developed in the precast modular grade crossings. Water collects at the low spots, which then reduces bearing capacity of the base, causing deterioration of the adjacent asphalt pavement. This deterioration causes spalling of the panels, and ride quality problems for motorists.

The Solution

CJGeo’s rail grouting experience includes dozens of precast modular grade crossing stabilization projects. Working with the rail system’s on-call MOW contractor, a CJGeo polyurethane grouting crew grouted each of the two crossings in a day, each.

CJGeo uses CJGrout 48NHL, which is specifically formulated for high dynamic load applications. 48NHL provides multiple factors of safety from a compressive strength perspective, but is slightly elastomeric, which makes it much more durable than mudjacking or traditional cementitious pressure grouting grouts sometimes used to stabilize modular grade crossings on a temporary basis.

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Facing a similar challenge to this Maryland concrete lifting project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Basement Wall Load Reducing Fill

The Job

This basement wall load reducing fill project is located in Lexington, Virginia, on a campus of Washington & Lee University. The scope is part of a new academic building construction project. The building will house the Williams School of Commerce, Economics & Politics.

The Challenge

The building is on a sloping site. The front of the building will be slab on grade, and the back half of the building will be a walk-out basement level. The transition between the two floors is an approximately fifteen foot tall wall with two 90’s.

The basement wall is designed to be braced by the floors and building. However, the floors & building couldn’t be built until the wall backfill was in place. In order to backfill the wall, it would need load reducing fill, or it would need temporary bracing.

The Solution

A structural engineer recommended the general contractor reach out to CJGeo about backfilling the wall with CJFill-Ultra Lightweight low density fill. Working with the structural EOR, geotech EOR & general contractor, CJGeo developed a backfilling plan that would allow backfilling the wall over three days while eliminating the need for temporary bracing.

CJGeo poured three lifts, each about 4.5′ deep. A dry batch process plant running at up to 200 cubic yards per hour backfilled the wall in three days.

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Facing a similar challenge to this basement wall load reducing fill project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Low Density Bridge Underfill

The Job

This low density bridge underfill project is located on Interstate 95, in Philadelphia, Pennsylvania. The scope is part of a large widening and reconstruction project. The bridge is located over Carver Street, just south of the Tacony-Palmyra Bridge.

The Challenge

As much underfill as possible had to be in place prior to the bridge demolition. Otherwise, it would have been impossible to demolish the deck, beams & other structures during a limited closure. There are also multiple underlying utilities which would not tolerate the nearly 5ksf of additional dead load from using traditional flowable fill.

The Solution

In order to fill up to the bottom of the beams, CJGeo designed a mass fill placement plan that stepped in at a roughly 1.5H:1V slope. CJGeo batched CJFill-Ultra Lightweight with a 40psi at 28 day minimum compressive strength using the dry batch process onsite, and placed at times more than 1,000 cubic yards per day.

Once the CJFill-UL was in place to complete this low density bridge underfill, the customer was able to demolish the bridge and beams, only need to bring in a few feet of crushed stone for the pavement base, and then pave the roadway to restore traffic. This was performed during an accelerated closure to minimized traffic disruption. The work took around two weeks, using the dry batch generation method.

Speak With An Expert

Facing a similar challenge to this low density bridge underfill project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Lightweight MSE Wall Backfill

The Job

This MSE wall lightweight backfill project is located near Chester, Virginia. The MSE wall is part of a ramp reconfiguration and lengthening project at the interchange of Rt 10 and Interstate 95. Specifically, this ramp is from westbound Rt 10 to northbound Interstate 95.

As part of the ramp lengthening and realignment, the ramp needed to shift out onto an existing embankment.

The Challenge

There was insufficient right of way to widen the embankment without acquiring additional right of way. In order to shift the road without acquiring additional land, the geotechnical engineer of record, Schnabel Engineering, recommended to building a mid-slope MSE wall. The wall design includes a lightweight reinforced and retained zone to eliminate any net change in load. Effectively, when the slope is notched for the MSE wall construction, the difference in fill density allows for increased height.

The Solution

The existing soils were rough 125lb/cuft, and the CJFill-Ultra Lightweight backfill is 30lb/cuft. This allows for two additional feet of fill depth for every foot of undercutting. The final MSE wall lightweight backfill design included a 140psi minimum 28 day compressive strength (ASTM C495).

It took three lifts to backfill the wall, which was at most eight feet tall, and roughly 150 feet long. A composite drain on the slope addresses and water migration through the soil slope, and ties into a gravel bed at the base of the CJFill-UL load reducing fill.

Speak With An Expert

Facing a similar challenge to this MSE wall lightweight backfill project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Box Culvert Void Filling

The Job

This box culvert void filling project is located near Fredericksburg, Virginia. The Virginia Department of Transportation owns and maintains the structure, which conveys a stream under a rural divided highway. As part of a rehabilitation project, extensive cracking in the structure (a double barrel six foot by six foot box), was being patched with repair mortar, and some cracks epoxied.

The Challenge

At the start of project, the general contractor discovered extensive voids outside of the structure. These voids were allowing significant amounts of the stream flow outside of the box culvert (piping). This was cause for concert regarding the specified repair mortar application and epoxy injection.

The general contractor reached out to CJGeo about filling the voids with grout prior to the patching and repair operation.

The Solution

CJGeo proposed grouting all the voids outside of the box culvert with CJGrout 35NHV61. 35NHV61 is a hydro-insensitive, structural polyurethane grout. Its NSF61 potable water certification makes it excellent for work on drainage structures.

The owner, Virginia’s Department of Transportation, required water testing before, during and after grouting. This water testing specifically looks for MDI. All of the water testing, which was performed by a third party environmental laboratory, found zero MDI in any of the water samples.

It took three days onsite to complete the grouting. Some hairline cracks that were still damp after the bulk box culvert void filling work. CJGeo grouted these cracks with a hydrophilic chemical grout to make them completely dry.

Speak With An Expert

Facing a similar challenge to this box culvert void filling project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

Massachusetts Lightweight Fill

The Job

This Massachusetts lightweight fill project is located at Boston’s Logan International Airport. It is part of Logan Forward continuing improvements to the airport.

The Challenge

As part of this project, the general contractor installed two cast-in-place barrier walls. The space between the barrier walls is between four and nine feet. The walls are curving, have non-vertical faces, and bear on a curving, non-horizontal existing podium slab. The gap between the walls needed to be filled in order to pour a housekeeping slab spanning between the walls.

This work is all on an existing podium structure. So, the fill density between the two walls had to be as low as possible.

The Solution

CJGeo proposed filling between the two walls with CJGrout 20SDB. 20SDB has a similar density and compressive strength to typical expanded polystyrene (EPS, or Geofoam) blocks. However, unlike geofoam blocks, 20SDB:

  • is pumped, so doesn’t require trimming, and fits to any shape
  • expanded onsite, so logistics are significantly simpler
  • cures within a few minutes, so is still quick
  • not affected by petroleum products

A CJGeo polyurethane grouting crew took a single shift onsite to install the 64 cubic yards of CJGrout 20SDB. The general contractor began installing the topping slab the next day.

Speak With An Expert

Facing a similar challenge to this Massachusetts lightweight fill project? Give us a call or send us an email by clicking on the state marker to locate the Preconstruction Manager that services your area.

Sheet Pile Joint Sealing

The Job

This sheet pile joint sealing work is part of the Thimble Shoals parallel tunnel project. The project is located between Islands 1 and 2 of the Chesapeake Bay Bridge Tunnel. The Chesapeake Bay Bridge Tunnel crosses the opening of the Chesapeake Bay, connecting Norfolk/Virginia Beach and the Eastern Shore.

The Challenge

Water was leaking out of a joint in the precast splash wall adjacent to the TBM slurry separation pit. Any time it rained, precipitation landing in the slurry pit would flow out of gaps in the sheet pile wall. It then passed through the roughly 3′ of soil between the sheet pile wall and splash wall, and then out through joints in the splash wall.

The Solution

CJGeo proposed using a single component, hydrophilic chemical grout to seal the joints. Hydrophilic grout is best for this particularly repair because:

  • the area is rather dynamic, so hydrophilic’s ability to flex and stretch without tearing helped to ensure longevity
  • the area is constantly exposed to moisture, so dimensional stability is not a concern.

A CJGeo chemical grouting crew of three people completed the sheet pile joint sealing repairs in less than a day. Some chemical grout extruded out through the joint in the splash wall. It was broken off flush with the surface and disposed of offsite.

Speak With An Expert

Facing a similar challenge? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

NY Grade Crossing Repair

The Job

10 panels of StarTrack modular grade crossing tubs settled in an urban street crossing owned by a short line. As a result of the settlement multiple clips broke. This caused the panels to pump.

The Challenge

The crossing tubs settled, and when crossed by trucks, pumped water containing the sub-ballast up between the tubs and adjacent pavement. The adjacent track also settled significantly.

The Solution

CJGeo proposed grouting immediately below the panels, and also into the underlying disturbed subballast using CJGrout 48NHL geotechnical polyurethane grout.

The CJGrout 48NHL was injected through 5/8″ holes drilled through the panels. The settlement pattern of each panel determines the specific hole spacing. It takes about five minutes for the grout to cure to 95% of its ultimate strength. After grouting, it’s important to tamp the approaches. Because the rails are clipped, lifting the panels lifts the rails & ties in the approaches. If the approaches aren’t tamped, the crossing can teeter totter, which is bad. Tamping is done immediately after grouting, and preferably before any rail traffic resumption.

CJGeo performed the StarTrack modular grade crossing repair without impacting rail traffic. The facility was able to function normally throughout the repair, which took less than a day.

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Facing a similar challenge? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

New York Tub Crossing Lifting

The Job

Eight panels of StarTrack modular grade crossing tubs settled. As a result of the settlement multiple clips broke. This tub crossing lifting project was for a short line serving an industrial facility in Geneva, New York.

The Challenge

The crossing tubs settled, and when crossed by trucks, pumped water containing the subballast up between the tubs and adjacent pavement. The crossing was the only entrance into an industrial facility that took two trains per day. Because of limited onsite storage, rail service couldn’t be disrupted at all.

The Solution

CJGeo proposed grouting immediately below the panels, and also into the underlying disturbed subballast using CJGrout 48NHL geotechnical polyurethane grout. CJGeo performed the tub crossing lifting work without impacting rail traffic, and the facility was able to function normally throughout the repair, which took less than a day.

Polyurethane grouting with CJGrout is an excellent alternative to cement based grouting, because:

  • CJGrout cures within a few minutes, so there are no limitations on rail traffic
  • CJGrout is not brittle, so does not break down in dynamic environments like thin layers of cement-based grout tend to do
  • CJGrout application is not weather dependent; in this case, it was snowing during installation
  • CJGeo controls the entire CJGrout logistics process, so there’s no need to wait on ready mix trucks or coordinate deliveries of material that goes bad within a few hours of offsite mixing

Speak With An Expert

Facing a similar challenge? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

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