Grace Industries, to date, has been awarded 19 contracts at the Rockaway Boardwalk project spread out over five phases. New boardwalk design will include raising it 3 feet higher than the 100-year storm elevation, and meeting the H-20 loading capacity. H-20 is the bridge design criteria established by the American Association of State Highway Transportation Officials, states the National Precast Concrete Association Foundation. It specifies truck axle loading of 32,000 pounds or wheel loading of 16,000 pounds. Within each phase, the contracts which Grace has been successful include:
Site Preparation, Salvage & Removals – Existing materials are salvaged, including metal railings, signage, World’s Fair benches and wood ramps. Remaining wood boardwalk is removed and disposed. Concrete piles, pile caps and deck is also removed and disposed. Once the existing structure has been demolished, any excavations are back-filled and the site is re-graded.
Pile Driving, Sand Retaining Walls and Pile Caps – Steel H piles are driven along with steel pipe piles. Precast concrete sand walls are set in between the H piles and grouted in place. Precast pile caps are set onto the steel pipe piles. A reinforced concrete plug is poured to connect the pile cap to the pile. Precast planks are set on the beach side in order to create pedestrian ramps from the boardwalk down to the beach. Utility relocation, generally water main, is provided as required. All grades and alignment are maintained to ensure the new boardwalk meets the existing islands that are to remain as part of the finished boardwalk.
Site work and Cast in Place Concrete – Form and pour all ramps and stairs on the land side from new boardwalk to street level, as well as new sidewalks and concrete curbs. In Phase 3 and 5, Grace’s value engineering switched cast in place ramps to precast planks which enabled us to work more efficiently in the winter months helping get the contract back on schedule. Site grading and re-establishment of any dunes disturbed during construction is performed. Some challenges encountered with this work included exposed aggregate stairs and blue glass ramps.
RPL Decking - Furnish and Install RPL (recycled plastic lumber) decking on concrete ramp and stair structures to give a traditional wooden boardwalk look, as well as RPL fascia along the outside of ramps and stairs. Also included are building wood stairs and ramps on the beach side of the boardwalk. New World’s Fair benches and custom seats made from reclaimed wood from the original boardwalk are furnished and installed.
Signage – Furnish and install all new boardwalk and lifeguard signs for all phases.