A Message from Project Leadership
Ryan Banas, Project Director
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The last several weeks have given us many reasons to celebrate on the HRBT Expansion. First, April 17, 2024, will be a day that lives in Commonwealth lore as Mary the Tunnel Boring Machine (TBM) completed her much-anticipated journey to North Island, broke through the headwall in epic style, and became Virginia’s first ever bored roadway tunnel. It was truly a day each and every team member will carry with them for the rest of our careers and one the region can proudly mark in the history books!
Second, but no less impressive, on May 2nd, just two weeks after Mary’s breakout, traffic began flowing on the new eastbound North Trestle. Vehicles traversing the new structure marked the first new bridge crossing the harbor at the HRBT in nearly 50 years.
These events serve as two massive milestones for the project and are a testament to the determination of the literally hundreds of construction workers, engineers, and others involved in making these a reality. While there is still much work to be done across the 10-mile project corridor, join us in taking a moment to recognize the efforts of Hampton Roads Connector Partners (HRCP), their subcontractors, design engineers, and consultants for the work they do every day to move us closer to an improved HRBT.
Thirty years after the need for a second crossing was identified, we are two giant leaps closer to having an improved crossing that provides increased capacity, eases congestion, and improves travel time reliability.
Drive Safe!
Ryan Banas
Project Director
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Proud Mary Makes History in Hampton Roads
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The Hampton Roads Bridge-Tunnel (HRBT) Expansion Project reached a groundbreaking achievement. Mary the Tunnel Boring Machine (TBM) has completed her journey from the South Island to the North Island, boring the first of two new tunnels. This monumental achievement represents the boldness and innovation of Hampton Roads, now home to the first bored roadway tunnel in Virginia and the third of its kind in the United States. The
landmark event is a major step forward in enhancing transportation infrastructure for the region’s residents and visitors.
The TBM was designed and built by Herrenknecht of Germany. It took approximately 14 months to fabricate the 46-foot-high machine, four months to ship it from Germany to Portsmouth Marine Terminal and another six months to assemble it for launch from South Island. Tunneling commenced in April 2023, and less the one year after beginning the first leg of her journey, our 4,700-ton marine mega drill named Mary successfully mined nearly 8,000 feet while excavating 750,000 cubic yards of soil.
The highlight of Mary’s first trip was an impressive record of 17 rings installed in one day. Reportedly, that’s the best day of production for any roadway tunnel TBM in the nation. In addition to lessons learned during excavation, the HRBT crew also picked up some unexpected artifacts along the way, including mastodon bone fragments believed to be as old as 50,000 years. Second only to Mary, the bones may be the most talked about part of the project. After installing 1,185 rings beneath the harbor’s seabed, Mary broke through to the North Island. She was welcomed by whistles and resounding applause from supporters and proud team members who contributed to her iconic arrival.
Before she can head back toward Norfolk, Mary must first undergo a five-month rotation period as the team realigns her one gantry at a time, to enter the second tunnel portal. After reassembly, she will begin mining the eastbound tunnel, a process expected to take about ten months. Stay tuned to the HRBT Expansion website, monthly newsletter, and social media channels for details on the technology and tools used to start Mary on her second and final voyage below the Hampton Roads Harbor.
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Construction Update
Recent and Upcoming Roadway Traffic Shifts on I-64 and in Hampton
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As roadway and bridge construction work on the HRBT Expansion Project advances, Hampton Roads Connector Partners (HRCP) construction crews have recently completed the project’s first permanent traffic shift onto a new structure.
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Eastbound I-64 HRBT North Trestle
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On May 2nd, a major traffic shift was implemented on I-64 east at the HRBT North Trestle. This activity diverted traffic to the new eastbound trestle. Crews will demolish the old structure and make room for the new westbound trestle.
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Aerial photo of the new eastbound I-64 HRBT North Trestle.
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New, east side of Mallory Street Bridge (photo taken from construction camera located at I-64 east on-ramp)
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By mid-summer, traffic on the Mallory Street Bridge over I-64 will be shifted to the newly constructed east side of the bridge. This shift allows for the demolition of the old west side of the bridge followed by construction of the new west side of the bridge. Information will be sent to residences and businesses in Phoebus prior to the shift to alert them of this upcoming change.
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Spring 2024 Project Update
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Nearly five decades! That’s how long it has been since motorists had a new water crossing across the Hampton Roads Harbor. Click on the link below to take a virtual tour with Project Director Ryan Banas as he escorts viewers through expansion work, from the new Mallory Street Bridge to the North Island where Mary’s cutterhead emerged in April. You will also walk through the new tunnel and stop at the South Island where crews are creating formwork for the egress corridor and dividing walls that will separate traffic inside the tunnel. Follow Mary as she clears the path for crews and machines to maneuver concrete segments into place with delicate precision. View the new superelevated South Trestle, learn about environmental resilience woven into the marine bridge designs, and see some of the work on 25 bridges being widened or reconstructed throughout the corridor.
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A view of the project's beam launcher setting a girder for the new I-64 W North Trestle into its final position.
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At North Island, HRCP performs maintenance on Mary to replace worn scrapers in preparation for boring of the second tunnel.
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Close-up perspective of the visible progress of North Trestle westbound.
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Tunnel construction continues at South Island as the formwork traveler helps develop the egress corridor and dividing walls for inside the tunnel.
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High Stakes Engagement: Connecting Regional Stakeholders
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Progress on the Hampton Roads Bridge-Tunnel (HRBT) Expansion Project is generating favorable reactions on both sides of the Hampton Roads Harbor. Team members are traveling from end-to-end informing stakeholders on the details of construction.
VDOT Hampton Roads District Engineer Chris Hall and HRBT Project Director Ryan Banas fielded questions from business owners and community leaders about the region’s high profile transportation projects during the April meeting of the Peninsula Chamber of Commerce.
Also in April, the Project Team joined the 2024 class of the Hampton Roads Chamber’s signature program, LEAD757 at The HIVE in Virginia Beach where community members from across the region gathered to learn about key issues and innovative problem-solving efforts underway in Hampton Roads.
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Regional Input. Regional Cooperation.
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VDOT and HRCP leadership on hand for HRBT Stakeholders Meeting 5-9-2024 in Chesapeake
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Stakeholder outreach this month included progress updates to the HRBT Expansion Project Regional Stakeholder Committee. HRBT project leadership and HRCP Connector Partners’ executives met with the stakeholders at The Regional Building in Chesapeake and expressed their shared commitment to improving regional connectivity and cooperation. Banas explained the latest expansion work, including Mary’s breakthrough, and Hall detailed the new 45-mile Hampton Roads Express Lanes (HREL) network of high-occupancy tolled and managed lanes along I-64 from Chesapeake to Newport News. Twenty-two miles of the HREL corridor are already operational.
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May is Military Appreciation Month
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The HRBT Expansion Project appreciates our men and women in uniform and those who served so faithfully. We are also grateful for the Virginia Beach Military Economic Development Advisory Committee’s (MEDAC) interest in the HRBT Expansion Project. Quality of life is foremost for this group of retired military leaders and civilians who strongly advocate for men and women who currently serve and have served our country. Improving quality of life through reliable transportation is also a VDOT commitment. HRBT Expansion Project Director Ryan Banas said, “It was truly an honor to share the great work being done at the HRBT Expansion with a group of such distinguished leaders." (5-20-2024)
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Staff from the Pennsylvania Turnpike Commission, interested in megaprojects like HRBT Expansion, traveled to Hampton Roads on May 15, 2024, to learn about best practices, financing and challenges associated with the expansion project. Pennsylvania is preparing to construct a new multi-million-dollar bridge between the Independence State and Delaware. The group toured the new tunnel with Project Director Ryan Banas, project personnel, and VDOT Hampton Roads District executives. They also learned about Virginia's electronic tolling systems.
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Pennsylvania Turnpike Commission staff joined VDOT District leadership, HRBT Expansion Project personnel on a tour of the new HRBT tunnel. Michelle Martin (ECSC Project Mgr.) points out how slurry is pumped out of the tunnel during excavation.
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Peers in Practice: Expanding Industry Partnerships
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HRBT Expansion Project Resident Engineer Todd Grifka was invited to address the annual Geotechnical Community of Practice meeting at the Virginia Transportation Research Council in Charlottesville, VA on May 13, 2024, to share project progress updates and design considerations for the HRBT tunnels. The presentation was attended by more than two dozen VDOT engineers from across the Commonwealth.
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Driving Diversity Across Hampton Roads
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Elonda Mackey
DBE/SWaM Manager, HRCP
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(Above) Elonda on site with on-the-job trainee,
David Alaniz and mentor, Razid Manjee
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In recognition of Small Business Month, May's employee spotlight is Elonda Mackey, HRCP's Disadvantaged Business Enterprises (DBE) and Small, Women, and Minority-Owned (SWaM) Manager. As the DBE/SWaM Manager, Elonda implements, monitors, and tracks contractual requirements to ensure diversity on the HRBT Expansion Project.
Elonda brings to the HRBT over 31 years of state government experience with her last stop as the New York State Thruway Authority’s Chief Compliance Officer. Now, she spends her workday fostering regional connectivity and economic inclusion here in Hampton Roads while serving as a bridge between the internationally recognized HRBT Expansion and those eager to make history.
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In addition to her team’s efforts to empower emerging enterprises, the DBE/SWaM Office is equally committed to exceeding the project’s workforce goals through hiring events and targeted outreach with the Minority Business Council (right), Hampton Roads Workforce Council, Women's Transportation Seminar, and Virginia Asian Chamber of Commerce. Elonda’s leadership doesn’t end there. She is also responsible for managing the project’s on-the-job training program where the next generation of industry professionals gain hands-on experience.
Elonda's optimistic and outgoing dedication to diversity and inclusion helps solidify the HRBT Expansion Project as a driving force behind local economic growth and ensures the project reaches its goals.
Beyond her professional achievements, Elonda finds joy in her family. Married for over 21 years to her supportive husband Troy, the pair share seven beautiful adult children. Outside of work and family life, Elonda enjoys traveling, working with children, and planning for retirement.
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Marine Construction Work Continues
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As warm weather and water activities start to rev back up this summer, Hampton Roads Connector Partners (HRCP)continues to update boaters about marine construction currently impacting local waterways.
Boaters must be aware of the ongoing construction work (including the presence and activity of barges, cranes, crew boats, pile driving, etc.) and exercise caution when operating boats in or near exclusion zones, mooring zones, and crane barges. As a reminder, mariners must maintain a minimum of 300 feet from all floating equipment.
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Hampton Roads Harbor/James River Impacts
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- Trestle bridges leading to/from the Hampton shoreline and the HRBT North Island
- Trestle bridges leading to/from the Norfolk shoreline and the HRBT South Island
- A Mooring Area, marked with buoys and lights, located in the Hampton Flats area of James River
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- Construction activity alongside both the eastbound and westbound lanes of Willoughby Bay Bridge
- A Mooring Area, marked with buoys and lights, located in Willoughby Bay in the vicinity of Willoughby Bay Bridge
- Safety Corridors and an Exclusion Zone are in place in the area adjacent to Willoughby Bay Bridge
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It’s job #1 on the Hampton Roads Bridge-Tunnel Expansion Project. To celebrate Safety Week (May 13-May 17) HRCP hosted a celebratory picnic at three work locations. More than 1,300 personnel are working diligently every day to improve the HRBT transportation corridor. We hope you’ll help us keep all of our employees safe by driving distraction free when you get behind the wheel. Thank You!
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Get In the Know, and Then Go!
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Sign Up To Receive Updates!
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Sign up for the HRBT Expansion Project Alerts to get weekly updates on traffic and construction impacts. Perfect way to “know before you go!”
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The HRBT Expansion Project team is committed to staying connected with the region for the life of the project. Like, join, follow, or tweet about the project on our social media channels.
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