I95 Sec. BR2 installation of steel curved tubular flange girder (TFG) span.The I-95 Betsy Ross Interchange Section BR2 project in Philadelphia aimed to enhance safety and traffic flow for the 160,000 vehicles traversing the interchange daily.
We recently had the opportunity to gain an inside look at this transformative infrastructure project through the perspective of Zakaria Alkaysi, a Transportation Construction Inspector with JBC. As part of his role, Zakaria was responsible for inspecting the BR2 construction site, ensuring that project components adhered strictly to the plans and specifications, and established construction standards. His involvement provided critical oversight during a pivotal phase of the build, helping maintain quality and compliance across the board.
In our conversation, Zakaria shed some light on the unique challenges the team faced — from navigating complex site conditions to coordinating across multiple disciplines — and the innovative solutions that emerged as a result. His insights offered a captivating glimpse into the technical rigor and collaborative problem-solving that define successful infrastructure development.
Navigating Underground Complexities
One of the most significant challenges involved boring underground beneath the northbound and southbound lanes of Interstate 95, particularly during peak travel hours. This demanding task required specialized equipment, materials, and chemicals to ensure the highway’s integrity. Obstacles such as large rocks and boulders frequently obstruct the boring machine, leading to breakdowns and requiring manual intervention to remove the materials. These difficulties significantly complicated pipe installation and the completion of inlet and manhole connections across the highway.
Collaborative Spirit in Unprecedented Times
The project’s timeline notably overlapped with the COVID-19 pandemic. Despite this, daily safety and compliance meetings were held among office staff, contractors, and subcontractors. Committees were established to coordinate work schedules and address issues, with weekly office meetings ensuring adherence to all tasks, codes, and regulations for everyone’s safety.
Innovations in Inspection
PennDOT introduced innovative electronic devices and techniques to boost work efficiency and prevent potential issues. A specialized computer with custom software was instrumental in improving the pile-driving process. This system monitored and confirmed the achievement of the refusal point (20 blows per inch) and ensured the rebound per blow was less than 1/4 inch. The computer also electronically logged hammer blows and stored data for analysis.
Additionally, a concrete scanner utilizing Ground Penetrating Radar (GPR) technology was employed to measure the depth of poured concrete on roadways and bridges. This device allowed inspectors to “see” through concrete, identifying features like thickness, rebar, post-tension cables, and voids, proving invaluable for locating hidden elements before construction or repair.
A Rewarding Experience
For Zakaria Alkaysi, the most fulfilling part of the project was the chance to collaborate closely with seasoned professionals whose depth of knowledge and hands-on expertise left a lasting impression. Working alongside these experts not only enriched his understanding of the field but also provided him with a front-row seat to observe advanced techniques in bridge demolition and reconstruction. Through this experience, he gained a deeper appreciation for the intricate planning, engineering precision, and logistical coordination required to execute such impactful infrastructure projects. The insights he acquired have significantly broadened his perspective on structural development and the real-world challenges involved in transforming complex designs into tangible, functional outcomes.
The BR2 Project, from its inception through all phases, served as an inspiration, fostering collaboration with a diverse range of professionals including designers, engineers, managers, inspectors, consultants, contractors, and subcontractors.
The project was recognized with the 2024 ASHE Delaware Valley Project of the Year award. JBC Associates is proud to have been a part of this challenging and ultimately successful project, contributing to enhanced safety and traffic flow for the community.
→ Sep 12, 2025
