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A Weeks Marine, Inc. Publication

Fall 2019

CELEBRATING

1

Est.

1919

YEARS

Contents Message from the CEO

3

Introducing J.S. Chatry

10

Tappan Zee Demolition

24

Recognition

4

McNally’s Cherry Street Lake Fill

16

North American Aggregates Plant

30

Weeks Community

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Collaboration - Tug Carolyn COI

22

Where is Weeks?

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Weeks Marine, Inc. Weeks Marine, Inc. is a family-owned business headquartered in Cranford, NJ. Established in 1919, the company is a leader in the maritime construction industry, and operates a network of regional offices in Louisiana, Texas, Hawaii, Ontario and Nova Scotia. For more information, please visit our website at www.weeksmarine.com. This newsletter is produced and distributed by Weeks Marine, Inc. and its subsidiaries. Thank you to the following contributors: Josh Campbell, Hamilton, Ontario; Ronnie Clifford, Cranford, NJ; Soraya Cortes, Cranford, NJ; Jameson Fellows, Covington, LA; Shane Harris, Houma, LA; Chris Hynes, Cranford, NJ; Meredith Jenusaitis, Cranford, NJ; Dru Kish, Cranford, NJ; Bob Manis, Perth Amboy, NJ; Charlie McCaskill, Covington, LA; Ed O’Donnell, Cranford, NJ; Veronica Sloan, Cranford, NJ; Ed Soehngen, Cranford, NJ; Brittany Scotland, Cranford, NJ; Tim Weckwerth, Covington, LA; Alexandra Weeks, Perth Amboy, NJ. Please send any suggestions or ideas to the editor: Jennifer D. Hamilton jdhamilton@weeksmarine.com EOE/AA M/F/Vet/Disability

Pictured above, second from right: Dick Weeks, Chairman. (1954)


Message from the CEO As we celebrate our first century in business, we are reminded of the pioneers that made this all possible. Our company began as a stevedoring operation in the Port of New York with just two cranes and has grown into the diverse operation it is today because of the strong business acumen of our leadership and the dedication of the people driving our operations.

We have all made a commitment here at Weeks Marine - to ourselves, our fellow employees, our clients, our community, and our environment - to make the most of our resources and capabilities so that we are positioned to make the greatest contribution we can to the future. I have no doubt that the next hundred years will be a showcase of our strengths and of our organization.

Rich Weeks CEO, Weeks Marine, Inc.

Pictured l to r: Joe Patella, General Mgr., Equipment/Yards, Construction; Dick Weeks, Chairman; John Devlin, Sr., Equipment Manager, Retired; Rich Weeks, CEO; Lou Neron, Project Manager, Construction; Rick Heltzel, Senior VP; and Eric Ellefsen, President.


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WEEKS MARINE, INC. · FALL 2019

RECOGNITION San Jacinto Marsh Restoration Awards

Foundation Impact Award On September 26, 2018, Weeks Marine received the Walter G. Bumphus Excellence in Leadership Award for demonstrating outstanding commitment to Louisiana’s educational system as a partner of Northshore Technical Communitiy College’s (NTCC) Maritime Transportation Program. The Louisiana Community and Technical College System (LCTCS) Foundation Impact Awards recognizes individuals, organizations, and business and industry, whose leadership efforts have been notably effective in advancing Louisiana’s education and workforce needs of students, businesses, and communities.

In Fall 2018, Weeks Marine’s restoration work at the Barbours Cut Expansion and San Jacinto Battleground Marsh Restoration Project in La Porte, TX, won at the 2018 Dredging and Port Construction Awards event in Amsterdam, Netherlands. The extremely challenging and successful project was selected for top honors in the Environmental Port Project of the Year category, and Inland Dredging Project of the Year, Majors category.

Weeks Marine began their partnership with NTCC in 2015 with the implementation of the Maritime Consortium, a group that has guided and built the maritime curricula to equip graduating students for the maritime industry. Tim Weckwerth, Noel Ramos, and Jessie Whittington attended the 2nd Annual Impact Awards Dinner in New Orleans to accept the honor. Founded in 1998, The LCTCS is made up of twelve openaccess two year colleges, and provides the best in academic services, cutting edge workforce development training, and inspiring adult education courses.

The Marsh Restoration was constructed by Weeks Marine and designed by the submitting firm, Atkins, in conjunction with the Enterprise Products Dock 8 Expansion Project in 2016. This project was also awarded the WEDA 2017 Environmental Excellence Award for Environmental Dredging, which Chuck Broussard, Jr., VP in Dredging accepted on behalf of the team in Vancouver, B.C.

Pictured, from l to r: Dr. William Wainwright, NTCC Chancellor; Tim Weckwerth, VP; Noel Ramos, HR Mgr.; Jessie Whittington, T&D; Dr. Tina Tinney, Chancellor at Nunez Community College; and Dr. Daniel Roberts, NTCC Acting Chancellor.


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NTCC Scholarships Awarded

Rutgers Dedication & Ribbon Cutting

On April 18, 2019, five scholarships sponsored by Weeks Marine were presented by Tim Weckwerth, VP, and Jessie Whittington, Training & Development, at NTCC’s Annual Chancellor’s Scholarship Breakfast in Mandeville, LA. The scholarships included two “Richard Weeks Maritime Endowed Scholarship” for existing students, one Electrician Endowment, one Welding Endowment, and one full scholarship to attend the the two-year Maritime Program.

“Richard Weeks Hall of Engineering”, a state-of-the-art facility for student learning and research, has been officially dedicated. The building anchors the School of Engineering complex on the Busch campus in Piscataway, NJ and is the most recent facility built as part of an effort to create a core of new STEM facilities on campus. This is the first Rutgers University building named for an engineering school alumnus.

PANYNJ Green Equipment Award On December 6 at the Port Authority of New York & New Jersey’s Year-End Briefing, Weeks Marine received the Green Equipment Award for lowering the carbon footprint at Greenville Yard in Jersey City, NJ. Bret Fischer, Facilities & Environmental Compliance, accepted the award on behalf of Weeks.

Pictured from l to r: Christopher Malloy, Rutgers–New Brunswick Interim Chancellor; Thomas Farris, School of Engineering Dean; Dick Weeks, Chairman; and Robert Barchi, Rutgers University President.

Distiguished Leadership Award On June 10 at Fort Hancock in Sandy Hook, NJ, Jason Marchioni, VP of Marine Services, accepted a Distinguished Leadership Award on behalf of Weeks Marine. Hosted by the Jersey Shore Partnership, the Summer Celebration event honors individuals and organizations that have made extraordinary contributions to the mission of shore protection and beach replenishment.

A special THANK YOU to WEEKS’ hard-working Equipment Department for their foresight in purchasing environmentally efficient machines!

Pictured, from l to r: Kevin Robinson, Business Development; Bob Manis, Business Development, NAA; Jason Marchioni, VP; Fred Troisi, Office Manager; Chris Camarote, Staff Engineer/QC Manager; and Eric Dickerson, NE Business Manager.


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WEEKS MARINE, INC. · FALL 2019

WEEKS COMMUNITY

NTCC Opens New Maritime Simulation Lab Unveils Timeline of Weeks’ 100 Year History

Pictured above: Dick Weeks tests out the school’s new simulator, which occupies one full room and can be programmed to simulate over 800 actual Ports and Harbors, along with varying vessel types, sea conditions, and weather patterns.


NTCC OPENS NEW MARITIME SIMULATION LAB

On August 11, 2019, Dick Weeks, Chairman, toured the new Weeks Marine Maritime Simulation Lab at Northshore Technical Community College (NTCC). Located just next door to the Richard Weeks Center of Innovation on the Lacombe, LA campus, the new lab features cutting-edge equipment that was purchased largely with funds donated by Mr. Weeks over the years. The lab will be used for both teaching maritime program curricula and hands on simulator training. “Having a state-of-the-art maritime simulation laboratory will allow NTCC to expand its program offerings and provide high-tech, relevant training experiences for the entire Northshore region,” said Randy Savoie, the college’s lead maritime instructor. “NTCC and Weeks Marine have strategically formed a partnership to advance maritime education in Louisiana in efforts to sustain longterm economic benefits, creating direct employment opportunities to fulfill the increasing maritime workforce gap.”

Pictured above l to r: Dr. William Wainwright, NTCC Chancellor; April Smith, NTCC Interim Dean; Dick Weeks; Dr. Jim Carlson, NTCC Vice Chancellor; and Brayden Goodreau, NTCC student and scholarship recipient.

Mr. Weeks was greeted by NTCC representatives and Brayden Goodreau, recipient of the Maritime Program’s 2019 full scholarship on behalf of Weeks Marine. Brayden and his parents traveled to NTCC for the opportunity to meet Mr. Weeks and personally thank him for his support. The new Advanced Technology Center at Northshore Technical Community College opened in September 2019 for the fall semester. This building houses the Maritime, Electrical, and Welding programs - each program includes students that were recent recipients of

Pictured above: Randy Savoie, NTCC’s lead maritime instructor, shows Mr. Weeks how to control the school’s mobile simulator, which can be transported for on-location demonstrations at events.

“Having a state-of-the-art maritime simulation laboratory will allow NTCC to expand its program offerings and provide high-tech, relevant training experiences...” Pictured above l to r: Dr. William Wainwright, NTCC Chancellor; Dick Weeks; Tim Weckwerth, Dredging VP; and Dr. Jim Carlson, NTCC Vice Chancellor.

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WEEKS MARINE, INC. · FALL 2019

WEEKS COMMUNITY Weeks Marine sponsored scholarships for 2019. Since 2015, Weeks Marine has served on the NTCC Maritime Consortium, guiding and building the maritime program curricula to ensure that graduating students are well equipped to meet the needs of the maritime industry. In addition
 to curricula counsel, programmatic support, and the hiring of graduates, Weeks Marine engages with NTCC students throughout the year by hosting career prep “lunch and learns” and by creating student internship opportunities. “Actively engaged partners like Weeks Marine dynamically refocuses education programs from the theoretical to the practical, providing mentorship, hands-on training and applicable work experiences that are critical to

student success” said chancellor Wainwright. During Dick Weeks’ visit to the new simulation lab, representatives from NTCC and Weeks Marine surprised him by unveiling an 18-foot timeline of Weeks Marine’s 100-year history. The timeline wall, commissioned by NTCC, was created as a tribute to Weeks Marine’s ongoing partnership with the school. It was designed by Louisiana based artist, Megan Barra, who worked closely with both the school and representatives from Weeks Marine to capture many of the company’s key milestones throughout its 100 year history. The timeline is now prominently displayed on a wall inside of the new lab, open to all students as of the Fall 2019 semester.

1934 Weeks Stevedoring Company is incorporated in New Jersey.

1919 Founded by father and son, Francis H. and Richard B. Weeks as the Weeks Stevedoring Company.

1950s The Weeks family began to expand into marine projects outside of stevedoring.

1952 Third generation: Richard N. Weeks joins the company.

1977 Fourth generation: Richard S. Weeks joins the company.


WEEKS’ 100 YEAR TIMELINE

Pictured above on left: Mr. Weeks views the timeline in the new Maritime lab. Pictured above on right, l to r: Tim Weckwerth, Dredging VP; April Smith, NTCC Interim Dean; Jenny Hamilton, Communications Director; and Jessie Whittington, Training & Development.

2001 Weeks performs all marine transportation services for 9/11 WTC recovery efforts in NYC.

1980s & 90s Period of marked growth for the company, and it changes its name to Weeks Marine, Inc.

1984 Weeks Marine’s first new build tug, Elizabeth.

2019 Weeks christens newest dredge, J.S. Chatry in Houma, LA & celebrates 100 years in business!

2017 NTCC’s Richard Weeks Center of Innovation opens in Lacombe, LA.

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EQUIPMENT HIGHLIGHT

Introducing

J.S. Chatry In August 2019, Weeks Marine christened the newest dredge to its fleet, J.S. Chatry. Built, outfitted, and designated to be used both inland and offshore, the cutter suction dredge is named in honor of Senior Vice President and head of Weeks Marine’s Dredging Division, J. Stephen Chatry.


Lowering of the superstructure including lever-room, crew quarters, and offices onto the main deck of the J.S.Chatry. Photo courtesy of Shane Harris


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WEEKS MARINE, INC. · FALL 2019

On Monday, August 12, 2019, Weeks Marine, Inc. christened the most highly automated and multifunctional ocean-going U.S.-flag vessel in its category, J.S. Chatry, at a ceremony in Houma, LA. Invited guests and selected media representatives toured the 310 ft. dredge, followed by a program introduction by Eric Ellefsen, President, who spoke about Stephen Chatry’s contributions to the company, saying, “His steady leadership has been the key to the Weeks Dredging Division’s growth over the last two decades.” Among the guest speakers were Louisiana State Senator Norbert (Norby) Chabert who welcomed the J.S. Chatry to the Louisiana dredging market, and the Coastal Protection and Restoration Authority’s (CPRA) Chairman, Chip Kline, who mentioned that he was pleased to hear that the J.S. Chatry’s first project would be in the Mississippi River at the Hopper Dredge Disposal Area.

Richard Balzano, Deputy Maritime Administrator at the U.S. Maritime Administration, commented, “the U.S.-flag maritime industry is thriving today, due in part to the creativity, leadership, and entrepreneurial spirit of companies like Weeks Marine and all its partners.” Rich Weeks, CEO, also spoke, honoring his father Dick for being the mainstay of Weeks Marine during its first hundred years and for laying a sound foundation for the next hundred. He thanked Weeks’ many partners and suppliers and closed by thanking Steve for his 21 years of service to Weeks Marine and for helping the company achieve sustainable growth. Steve’s daughter, Amanda Chatry, closed out the program by breaking a ceremonial champagne bottle over the dredge’s 8.5’ cutterhead.

Pictured above from l to r: Steve Chatry’s daughter, Amanda, after breaking the champagne bottle. Employees Teddy Stelly, Chief Engineer; Paul Marino, Chief Engineer; Eric Ellefsen, President; Steve Chatry, SVP; Robert Guidroz, Captain; and Mark Hale, Captain, aboard the new dredge. Pictured below from l to r: Alexandra Weeks, Director NAA, with daughter, Eleanor; Richard S. Weeks, CEO; Dick Weeks, Chairman; and Katherine Weeks. CPRA Chairman, Chip Kline, at the controls in the lever-room.


INTRODUCING J.S. CHATRY

Pictured above: members of Weeks’ Dredging Division Engineering team that were heavily involved in the construction and completion of J.S Chatry. Below, full view of the new 310’ dredge at the Christening event in Houma, LA.

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WEEKS MARINE, INC. · FALL 2019

J.S. CHATRY

J.S Chatry 310 ft. x 72 ft.

WEEKS VENTURE

Venture 195 ft. x 41 ft.

Total Installed Power

Fuel Oil Capacity

Installed Dredge Pumps

J.S. Chatry Venture

J.S. Chatry

22,264 hp 8,825 hp 337,000 gal. J.S. Chatry

Venture

90,000 gal. Venture


INTRODUCING J.S. CHATRY

The $60 million investment in this new oceangoing 30-inch hydraulic cutter suction dredge will strengthen Weeks Marine’s presence in the national coastal restoration and protection market, one of the fastest growing in the dredging industry. The dredge, named for J. Stephen Chatry, Vice President and head of Weeks’ Dredging Division, embodies the technical advances of modern dredging.

The most cutting-edge U.S. vessel in its category, J.S. Chatry will be able to dredge a wide variety of materials, including cemented sediment, clay, and sand, all while meeting federal environmental standards. The ability to dredge nearly all types of soils and rocks that are ill-suited for trailing suction hopper dredges and mechanical dredges gives cutter dredges an advantage over their counterparts.

“I am very happy and proud that our newest dredge is named for Steve. He is a lifelong Louisianan and has been a key member of our team as we have grown the business in Louisiana and throughout the United States,” said Rich Weeks, CEO.

J.S. Chatry will be powered by GE’s Tier IV diesel engines, and boasts a total installed horsepower of 22,264 with 3,000 hp on the cutter-head. The 310-foot-long, 72-foot-wide dredge is a testament to technical and engineering advances, which are highlighted when compared to one of Weeks’ first cutter suction dredges, Venture, built in 1958.

Dredging Depth

Spud System

Utilization Venture

Venture

J.S. Chatry Inland

Venture

45 ft.

Fixed

Walking J.S. Chatry

J.S. Chatry

100 ft.

Inland

Offshore

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WEEKS MARINE, INC. · FALL 2019

“The power electronics and automation in the J.S. Chatry are a huge step forward. These advances allow precise control of the dredge functions which help us maximize productivity. It also has a more efficient sliding spud carrier built into the hull,” said Shane Harris, Senior Project Manager/Senior Electrical Engineer. “And the Tier IV (emission standard) hits the highest EPA rating for environmental efficiency compliance requirements,” said Harris. Charlie McCaskill, Vice President in the Dredging Division, noted some of the technological advancements over the Venture, including more than twice the dredging depth, three times the pumping distance, four times the swing power, five times the cutter power, and a walking spud system versus one that is fixed. Another noteworthy advancement of J.S. Chatry is its ability to work offshore. “One of our design parameters was to build a vessel that has better seakeeping ability,” McCaskill said. “As sea conditions worsen, a dredge will obviously have to stop digging at some point. We wanted a vessel that could continue working in rougher sea conditions compared to the other dredges in our

Weeks’ first cutter suction dredge, Venture, Us, sentiLouisiana ipsus aswetlands distint, nimin consed earit dolores volupti berchil building in 2009. ignitiocourtesy sanihil of eos dolupitSaragusa intotatur andipiet qui aut arupturitis volor Photo Vincent

fleet.” When the dredge is not at sea, J.S. Chatry is equipped with a walking spud carriage for efficient work in inlets and navigable waterways. In October 2019, J.S. Chatry joined ongoing dredging work at the Head of Passes project in the Mississippi River Ship Channel near Venice, LA. Weeks Marine will dredge 12 million cubic yards from the existing Hopper Dredge Disposal Area, to create an additional thousand acres of wetland in the Delta Wildlife Refuge, Pass A Loutre Wildlife Refuge, and the New West Bay marsh creation area. “J.S. Chatry is the next advance in technology, efficiency, and productivity,” said Eric Ellefsen, President. “I am excited about what it means for both Weeks Marine and for the capacity of the nation’s dredging industry.” The coastal protection and restoration markets are growing, and the addition of the J.S. Chatry is a strategic decision to further our commitment to the dredging industry.


INTRODUCING J.S. CHATRY

Expanding into Dredging Weeks Marine expanded its operations to include dredging around the 1950’s, utilizing its cranes initially used for stevedoring operations - to move into the new market. It wasn’t until later that the company acquired its first cutter suction dredge, Venture, built in 1958. The use of suction dredges can be traced back to 1867, when French engineer Henri-Emile Bazin suggested the use of pumps for dredging rivers, leading to the development of the first suction dredges that were used in building the Suez Canal. Suction dredges became more common following the successful completion of this vital channel in 1869. By the end of the 19th century, the cutter head was developed to deal with harder soils and rocks, overcoming the limitations of traditional suction dredges.

Charlie McCaskill (on left) and Steve Chatry review construction progress at Weeks’ Houma Yard in Louisiana. Photo courtesy of Guy Guidry

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WEEKS MARINE, INC. · FALL 2019

PROJECT SPOTLIGHT

Cherry Street Lake Filling Project Toronto, Canada


McNally International Inc. A WEEKS MARINE COMPANY


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WEEKS MARINE, INC. · FALL 2019

Figure 1 Artists Rendition of Completed Port Lands Flood Protection Project

Figure 2 Revetment During Construction

Project Team Project Manager

Josh Campbell Jeff Reid Project Coordinator/Surveyor:

Julian Mendoza

Project Coordinator:

Mattis Descorte

Project Supervison:

Devan Wood Radek Szulc

Weeks’ Canadian subsidiary, McNally International, Inc., has been awarded a subcontract for the Cherry Street Lake Filling (CSLF) Project, one part of a much larger revitalization program for the Port Lands of Toronto. This area, immediately east of downtown Toronto, represents over 1,000 acres of under-utilized real estate. The program will seek to restore the mouth of the Don River and create a new river valley for channeling flood waters. As part of this project, new wetlands will be created along with a new community called Villiers Island. McNally’s subcontract represents approximately $6 Million of the $65 Million CSLF project, which in turn is part of the overall $1.25 Billion Port Lands Flood Protection Project. Figure 1 shows the concept rendering of the proposed finished product, with the front face of the revetment we are working on highlighted in blue. McNally’s subcontract involves the placing and shaping of aggregate materials for this revetment stretching from the end of the existing Keating Channel to the outer edge of Pier 35, covering a distance of approximately 325 meters. Included with the revetment work is the installation of fish gate structures and marine landscaping. Figure 2 shows the status of the work in November 2018. In this image, you can see the core stone starting to take the shape of the revetment and the reclamation fill being placed by others behind it. The inside slope of the revetment was completed first and covered in geotextile so that the reclamation fill could be placed prior to McNally completing its work. The revetment installation began with several large cargo vessels bulk placing core stone near the revetment site. After this, a total of approximately 25,000 cubic meters of core stone was relocated and/or shaped to form the base of the revetment. This is a significant increase over the contract quantity of only 10,000 cubic meters due to issues with the placement accuracy from the cargo vessels.


CHERRY STREET LAKE FILLING PROJECT

Figure 3 “Drowned Tree” with concrete anchor

As the bulk placement was not within the contract, a significant change order was negotiated for the increased quantity, thus increasing the project budget. After areas of the core stone were approved, subsequent layers were placed consisting of an additional 11 types of material totaling over 15,000 cubic meters. These layers include armor stone for protection of the revetment, habitat stone for fish habitat, and landscaping materials such as beach gravel. The level of detail required by the architects is significant, with various cross sections and layers, some of which will not be easily visible to the public. Unique to this project are some of the marine landscaping requirements, which include the planting of Drowned Trees and placement of Rootwads around the structure. Figure 3 shows the design for the Drowned Tree, which is a dead tree with a concrete anchor buried in the core stone to hold it upright. Figure 4 shows the mock-up of the Rootwad, which is a tree trunk with the roots still attached, anchored by boulders. The purpose of these is to create a natural looking wetland similiar to what is seen in Figure 5.

Figure 4 Rootwad Mock Up

Work remains on schedule with the bulk of the in-water work completed in September 2019 with final shore work finished in October. However, the overall project will still have several more years before it reaches completion. With this remaining work, there may be potential for additional marine based contracts to bid on depending on the final designs for the remaining sections. Figure 5 Artist’s Rendition - Finished cove with Rootwads

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WEEKS MARINE, INC. · FALL­­ FALL 2019


Healy Tibbitts Builders A WEEKS MARINE COMPANY

COLLABORATION OF DIVISIONS

Weeks Tugboat Carolyn Fully compliant with Subchapter M regulations A joint effort by Weeks’ Marine Services Division, Regulatory Compliance, and Healy Tibbitts Builders, Weeks’ Hawaiian subsidiary, has successfully brought the Hawaii-based tugboat Carolyn into Subchapter M compliance. The U.S. Coast Guard’s (USCG) Subchapter M regulations govern the design, construction, equipment, safety protocols, certification, records, and operation of towing vessels. Weeks Marine continues to lead the way in achieving compliance with these enhanced safety standards for its towing fleet. In January 2019, a team comprised of Ronnie Clifford, Safety & Compliance Officer - Towing, Steve Brunswick, Regulatory Compliance Officer, and Kevin Pointer, Regulatory Compliance Specialist, traveled to Hawaii and met with John Juettner, Equipment Manager, Jeremy Aguiar, Deckhand, Cristian Caicedo, Marine Operations Manager, and Captain Scott Cooper of Healy Tibbitts to begin the evaluation for Subchapter M regulations. The week-long visit consisted of extensive time spent aboard the Carolyn and a deep dive into the vessel’s operations and records. Together, they were able to gather clear objectives and action items to ensure the Carolyn would be ready for its USCG inspection to determine Subchapter M compliance in March 2019.

Following the visit, Marine Services and Healy Tibbitts worked tirelessly to create a Health and Safety Manual and other necessary documents for compliance with Subchapter M regulations. The vessel also underwent its dry docking requirement, whereby a towing vessel must be dry docked twice within a five-year period to further ensure that the vessel meets the applicable safety standards. In March 2019, Ronnie Clifford returned to Hawaii with Chuck Cobb, Regulatory Compliance Supervisor, and Bryan Rolig, Regulatory Compliance Specialist, to train the crew of the Carolyn, including running through drills and readying the vessel for its upcoming inspection with USCG. The USCG inspector acknowledged the excellent condition of the vessel and routed the Certificate of Inspection (COI) to the Captain of the Port for approval. As a result of the collaborative efforts of Marine Services, Regulatory Compliance, and Healy Tibbitts, the Carolyn was issued its COI in May 2019 and is in full compliance with Subchapter M. Other vessels in Weeks’ fleet that have been issued their COI in 2019 are the Elizabeth, Katherine, Thomas, and Alexandra.


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WEEKS MARINE, INC. · FALL 2019

PROJECT SPOTLIGHT

Tappan Zee Bridge Tarrytown, New York


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WEEKS MARINE, INC. ¡ FALL 2019

WEEKS 531 working in close quarters between the new and old Tappan Zee bridges.

Weeks Marine played a significant role in building the bridge pier protection system for two main piers of the Tappan Zee Bridge in 1998 and later in its demolition and disposal in 2018. Spanning the Hudson River in New York, this vital thoroughfare connected Rockland and Westchester counties and served hundreds of thousands of travelers each day. Weeks Marine, with joint venture partner Grow Tunneling (now a part of Kiewit), constructed the bridge pier protection system from designs provided by URS Greiner from 1998 to 2000. A total of 56 precast T-beams were installed on a foundation of 96, 48-inch diameter pipe piles. These steel piles were driven up to 140-feet into the riverbed, with the final capacity of each pile between 500 and 750 tons. Once all the precast was in place, closure pours were made to connect the precast. Watertight cofferdams were installed around the post-tensioning ducts. The bundled tendons, ranging from 206-feet- to 361-feet-long, were installed and jacked to 360 kips (1 kip equals 1,000 pounds-force). A mini-batch plant was set up on the barge for grouting the tendons. Following the post-tension work, Weeks and the Grow Tunneling teams installed handrails, ladders, stairs, and ultra-high-molecularweight polyethylene facing on the exterior of the fenders, completing the project.

Bow of the massive WEEKS 531 crane barge.

On October 6, 2017, the Tappan Zee Bridge was officially retired after 62 years of service and the new 3.1-mile state-of-the-art, twin-span Governor Mario M. Cuomo Bridge was opened to the public. Weeks Marine returned to the site of the iconic bridge, now standing beside the newly constructed bridge, to demolish and remove the pier protection system. The planning phase and removal of the precast fender panels and supporting steel piles at the main span of the Tappan Zee Bridge presented unique challenges for Weeks’ engineers and 15-member demolition crew. One pre-demolition issue was how to gain access to sections of the fender system located beneath the low-lying bridge. An engineer-designed ballast barge with a forklift-like structure, one of the largest ever to be built by Weeks Marine, was the answer. When the ballast tanks were filled with seawater, the end of the barge with the forks sunk below the fender structure. Two tugs then slid under the fender structure and the ballast was reversed by pumping it back to the other end.


TAPPAN ZEE BRIDGE

This action enabled the section to be towed from beneath the bridge to a crane, which then lifted the section onto a deck barge. Engineers also had to calculate how to safely move the 300 to 450 ton sections onto the barge. The solution led to a company first – the deployment of the W531 to metro New York. Based in Louisiana, the 500-ton capacity Clyde 42 floating crane is one of the largest in the company’s fleet and was towed to New York just for this job, according to Dru Kish, Project Manager. “The 420-foot-long, 100-foot-wide working-offshore crane sits 19 feet out of the water and can house up to 100 workers,” Kish said. “It was the first time it was in the Hudson/New York area for Weeks Marine. It normally works in the Gulf region.” Engineers wanted to ensure that the W531 would fit in the tight space between the new and old bridges. Rhino 3D technology was used to accurately and effectively position the crane between both bridges. The 3D model demonstrated that the boom and its A-frame could, in fact, rotate 360 degrees without colliding into either bridge.

WEEKS 531 lifting the nose section of the ice breaker.

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WEEKS MARINE, INC. · FALL 2019

Once work began, employees of the subcontractor Cutting Technologies International, Inc. (CTI) used a diamond-encrusted wire to cut through the concrete. “Once the cut was made, a diver would put the wire around the pile at its base and cut it off,” according to Ed Soehngen, Project Superintendent. The special barge was then moved into position to access one of the 16 cut sections to be removed from under the bridge. “The CTI crew really did a fantastic job for Weeks given the challenges they faced,” noted Kish. After all the concrete sections had been removed, divers experienced several problems above and below the river’s surface. Extreme cold weather which created large ice chunks on the river prohibited divers from accessing the pilings for six weeks. After conditions improved, sandy sediment at the mudline sank back into place every time divers tried to create the necessary angle to cut the pilings. The solution was to utilize a clamshell bucket on a crane to excavate an area around the pilings, enabling divers to access the piles at the required elevation.

Weeks Marine crew deploying concrete road deck panels from the old Tappan Zee bridge to create an artificial reef along the south shore of Long Island, NY.

A total of 17,500 tons of concrete, steel pipe pile, and steel beams from the superstructure were used to create five artificial reefs around Long Island. Working in cooperation with the New York Department of Environmental Conservation, a reef barge transported materials to GPS-specific locations and offloaded them to create artificial habitat and spawning sites for aquatic life. New fishing opportunities were established at Fire Island, Hempstead, Moriches, Rockaway, and Shinnecock reefs during the 15-month reclamation project. “I’ve said many times that this is a real win-win for everyone,” said Ed O’Donnell, Transport and Disposal Superintendent. “It creates an aquatic habitat and repurposes materials that meet federal standards that would otherwise end up in a landfill. The fishermen really love this, too.” An additional 84,000 tons of concrete was crushed into tiny pieces and used as fill at North American Aggregates, a subsidiary of Weeks Marine based in Perth Amboy, NJ.


TAPPAN ZEE BRIDGE

The concrete recycled at the site helped rehabilitate and meet Federal Emergency Management Agency standards for restoration of shoreline destroyed during Hurricane Sandy and to raise grade at the Perth Amboy site. With the demolition and removal of the fender structure now complete, this project has come full circle for Weeks Marine. Weeks Marine employee Frank Campion was fortunate to be involved with the original build as well as the demolition of the fender system. “It was interesting to build and to deconstruct, and I actually thought I’d never be around to see it come down,” Campion said. “It’s not often you get to be involved with both ends of a project.”

Project Team Project Manager

Dru Kish

Project Engineer

Tim Straut

Project Superintendent

Ed Soehngen

Transport and Disposal Superintendent:

Ed O’Donnell

WEEKS 531 removes the cut fender section that weighs 350 tons for disposal.

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North American Aggregates A WEEKS MARINE COMPANY

NAA’s Perth Amboy facility is strategically located with easy access to major highways and waterways.

With over 500’ of operational bulkhead, NAA can efficiently load multiple barges for delivery to waterfront sites throughout the tri-state.

Processing Plant Construction

NAA’s state of the art screen plant and screen tower.

North American Aggregates’ (NAA) transformed the vacant site in Perth Amboy, New Jersey purchased in 2016. The new material processing plant has been under construction since June 2018 and officially opened in October 2019. During construction, the site was strategically utilized to continue the processing of sand, and the plant can now process 1,500 tons of material per hour, tripling the current production rates. The process begins with NAA’s trailing suction hopper dredge, Eleanor, mining virgin source aggregate from the Ambrose Federal Navigation Channel. The ocean mined sand is then transported to the Perth Amboy facility where it is drawn into the process stream. It is then conveyed to specialized heavy-duty wet screens, blending and mixing stations, rinsing areas, and stockpiled over two reclaim tunnels and product load-out areas. The state-of-the-art material processing plant is equipped to be a one-stop-shop for aggregate supply.

The fleet of 982M wheel-loaders cuts loading time by one third.

Developments will continue in Perth Amboy with the addition of two new E-cranes, currently in fabrication in Belgium. Utilizing electricity for operation, the E-canes will increase unloading the Eleanor in under five hours. Scheduled to be installed in early 2020, the new E-cranes will contribute to the company’s commitment to sustainability.

NAA sand is used as a top cover in the Kearny, NJ Landfill.


WHERE IS WEEKS?

WHERE IS WEEKS? Little Island at Pier55 Construction Project, Hudson River, New York, NY

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Fall 2019 ¡ www.weeksmarine.com

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Weeks Marine Fall 2019 Newsletter  

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