Archive for Projects

SunGlow Pier Restoration – Daytona Beach Shores, FL – 2018

The pier was in significant distress from corrosion damage. The original steel H piles had been encased in concrete and when that went into failure, the piles were wrapped in plywood.  Not state of the art corrosion control.

Our engineering assessment revealed that immediate repair was necessary and our repair design pointed toward new piles and bents as the most cost effective solution. Based on product availability and value engineering we settled on corrosion inhibited reinforced concrete piles, timber bents and all stainless steel fasteners.

The contractor was awesome at battling tides and weather and the project was completed after about 6 months. The restoration was a local tourist attraction and the engineering team and contractors were treated like rock stars! All the neighbors greatly appreciated the upgrade. The new pilings and bents are good for another 40-50 years!

Florida Bridge Cathodic Protection Projects (2013 – 2016)

Between 2013 and 2016 Existing Structures Engineering (ESE) provided Cathodic Protection Specialist and Testing services on fifteen (15) different FDOT Bridge rehabilitation projects across the state of Florida. Testing services provided included reinforcing steel continuity on bridge bent cap repair; adhesion, continuity to steel reinforcing and thickness measurements for zinc metalizing of steel and concrete surfaces; installation of structural and non-structural galvanic pile jackets; and commissioning of ICCP (Impressed Current Cathodic Protection) systems on bridge support structures.

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Freshwater Corrosion – South Florida Water Management District (2015)

Although the coastal environment is known to be very corrosive, it should come as no surprise that “fresh water” structures can also need significant maintenance to stay serviceable. Because fireworks fallout and fertilizers, some of the theme park water we have tested is nearly as corrosive as seawater. But these flood control structures that we evaluated the service bridges on are as “out in the middle of nowhere” as you can get. But natural tannins, fertilizer and age still take their toll.  These flood control structures are being refurbished and we confirmed that the service bridges are structurally suitable for light construction traffic (but never crane load a hatch or trench cover!).

Antenna Support Rack (2012-2013)

ESE was commissioned to design two roof-mounted racks to support antennas weighing approximately 4000 Pounds each. The roof-mounted racks were to be attached to the roof framing atop a building located on Cape Canaveral’s Air Force Station. ESE had to first confirm the as-built drawings of the roof plan. Next, the conceptual design was roughly detailed and submitted. Once this preliminary design was approved by the client, the detailed design was modeled using STAAD.Pro to perform a structural analysis. An AISC code check was executed on all steel elements. A stress analysis indicated that all stresses were within allowable and the structure passed on code and statics checks. ESE provided ongoing support during fabrication and installation of the antenna racks.

Illinois Marine Towing Syncrolift (S-1225) (2012)

Oldest Structure Yet! ESE was brought in specifically to evaluate the effect of corrosion on the IMT Syncrolift located in Lemont, IL. The mechanical lift dock was commissioned in 1969 and has been in use ever since.

During the ultrasound inspection of the scantlings, the Engineers were surprised to find riveted main transverse beams. Riveted construction has been out of use since the mid 1940’s.

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Ocean Royale, Indian Harbour Beach, FL, Balcony Restoration (2011-2012)

Ocean Royale started as a typical balcony restoration project. However, once the edges of the balconies were opened, the severity of the Post Tension (PT) cable damage was uncovered.

ESE determined that it was more cost effective to replace every PT anchor in the east edges of all balconies. This meant taking twelve inches of concrete off of each edge and creating access holes every three feet at about three feet in from the edge to feed new PT cables ends through the new concrete edge.

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Ocean Sands North, Indialantic, FL (2010 – 2011)

Ocean Sands North is located in Indialantic, FL.

Due to the harsh coastal environment and previous improper repairs, the balconies were severely damaged beyond economical repair.

Falling edge debris caused pool closure prior to restoration.

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Harbour Ridge Golf Course, Culvert Inspections (2008 – 2009)

ESE was hired by the golf course community to determine the condition of multiple underground steel culverts which connected various lakes around the course.

Some culverts ran under roadways which caused a need to ensure long term safety of the residents.

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JEA – Concrete Restoration of Unit #2 Cooling Tower (2005-2006)

JEA Cooling Tower (Jacksonville Electric Authority)Jacksonville Electric Authority/Florida Power & Light Company operates two coal fired 640 MW power plants at the St. Johns River Power Plant in Jacksonville, Florida. Corrosion related damage to Unit #2 Natural Draft Cooling Tower had progressed to the point where structural integrity and safety was a concern. The tower was built in 1985 (at a cost of over $50 million) and is 450 feet high and 320 feet in diameter. Existing Structures Engineering, Inc. (ESE) was hired to perform an engineering condition survey coupled with recommendations, and repair/remediation design. The scope of the project ultimately grew to include construction engineering and inspection.     Read More