URETEK ICR

A p o r t i o n o f t h e C a p e H a t t e r a s F e r r y Te r m i n a l ’s s e a w a l l w a s i n s e r i o u s n e e d o f re p a i r. T h e s e a w a l l n e e d e d a s o l u t i o n t o p re v e n t f u r t h e r d a m a g e a n d e n s u re s a f e t y t o t h e a re a .

Seawall stabilizationTHE CUSTOMER

Hatteras, North Carolina is home to the iconic Cape Hatteras Lighthouse, boasting over 50 miles of beautiful shoreline. While the year-round population is about 3,000-4,000 people, this number spikes in the summer months to over 50,000+ visitors per week. The Coast Guard Station at Hatteras Inlet is also located on the southern end of the island. The nearby ferry terminal for this wonderful island is both necessary, and enjoyable for residents and visitors alike.

CustomerNorth Carolina Department of

Transportation

LocationHatteras, North Carolina

TypeInfrastructure

Interesting FactHatteras Island is part of

the Cape Hatteras National Seashore, over half of the island

is undeveloped, natural terrain.

Ferry Bulkhead Details

THE CHALLENGE

When the original seawall was constructed, the concrete piles were installed using water jetting, a process of using high pressure water to create cavities to install concrete piles into the ground to support structures above. Once the row of piles were in place, concrete panels were set and sealed in between the piles. The seal between the precast panels and the piles at the ferry terminal were causing soil to pull through the wall, and into the ocean. As a result, sinkholes began to form behind the seawall near the Coast Guard Station Hatteras Inlet. The NCDOT contacted URETEK for an environmentally friendly, non-invasive solution to prevent further loss of soil behind the seawall.

THE SOLUTION

In order to fi l l the present voids and sinkholes in this environmentally sensitive area, injection of URETEK’s hydro-insensitive structural polymer, also known as high-density polyurethane resin, along the seawall would need to take place. URETEK’s Deep InjectionTM Process would allow the polymer material to expand, cure, and therefore fi l l any present voids or sinkholes. The process would also seal the panels and piles from the back side of the wall, preventing the future formation of sinkholes.

To start the project, the joints of the panels needed to be located with the help of trained divers who would also provide a l ive-stream video of the repair process for quality assurance. Next, injection tubes were driven down to depths of 20 feet along the seawall, and technicians then began to inject the URETEK polymer material. Extra precautions were taken during injection, to ensure the project would be non-disruptive to the environment and Hatteras residents.

THE RESULTS

All soil leaks were successfully repaired, the sinkholes forming behind the wall were fi l led, and the soil was stabil ized. The newly sealed joints, insured a stable, and functioning ferry terminal for residents, and vacationers alike.

URETEK ICRuretekicr.com | 800.240.7868