The Chesapeake Bay Bridge-Tunnel expansion in Norfolk, Virginia, is a groundbreaking tunnelling project aimed at improving connectivity between Virginia Beach and the Eastern Shore. The new parallel tunnel will help ease traffic congestion and provide a safer, more efficient commute for thousands of travelers daily. Spearheaded by the Chesapeake Tunnel Joint Venture (CTJV), a collaboration between Dragados USA and Schiavone Construction Company, this project is a significant engineering endeavor led by ACS Group. As iPS Powerful People, we are proud to be involved in this project.
The breakthrough moment
On Monday, January 27th, 2025, a historic milestone was reached as the tunnel boring machine (TBM) Chessie successfully broke through the receiving pit on Island Two at Thimble Shoal Channel. The breakthrough was a deeply emotional moment for the dedicated team, many of whom had been involved in the project since its inception in October 2017. Overcoming numerous challenges, the team celebrated this achievement with a live-streamed event on YouTube. Following the breakthrough, all project participants gathered for a commemorative group photo, capturing their pride and happines in this monumental success.
Chessie the TBM
The tunnelling process was executed using a EPB TBM, designed and manufactured by Herrenknecht of Germany. Measuring 43 feet in diameter and extending 308 feet in length, Chessie was aptly named by then-sixth grader Grace Bentley through a regional contest. During its operation, Chessie excavated approximately 500,000 cubic yards of soil and installed nearly 10,000 concrete segments, each weighing 10 tons.
Challenges and milestones
The project faced a major setback in May 2023 when Chessie encountered an unexpected obstacle—a buried anchor beneath the Bay bottom. The presence of steel fragments on the TBM’s conveyor belt led to the discovery of anchor remnants, which required extensive repairs. Of the 442 cutting tools on Chessie’s cutterhead, 389 needed replacement, along with 48 wear plates, each weighing 150 pounds. This unforeseen complication resulted in an additional 241 days of work and a seven-month maintenance period.
Despite these challenges, Chessie resumed excavation and successfully completed its journey in January 2025. The key excavation phases spanned from February to June 2023 and April 2024 to January 2025, marking significant milestones in the project’s timeline.
Team contributions & achievements
The success of the project was made possible through the relentless efforts of skilled professionals. iPS, a key partner in the initiative, provided round-the-clock experienced tunnelling specialists, covering roles from Superintendent to MSV Operators.
Ruben Piqueras, the Equipment & Plant Manager, expressed profound gratitude for iPS’s contributions, stating, “Without iPS, we wouldn’t have been able to succeed with this project.”
Impact & future prospects
The new tunnel will significantly enhance transportation efficiency by dedicating two lanes of traffic southbound, while the existing tunnel will handle northbound traffic. This improvement is expected to reduce congestion and enhance commuter safety.
With the breakthrough completed, the next phase involves disassembling the TBM, followed by the construction of the roadway, installation of electrical and mechanical systems, and development of support buildings. The final project completion is anticipated in early 2028.