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Woody Seat bridge: contractor error leads to epoxy overlay repair at no city cost; 2‑year warranty added
Summary
After detecting surface defects in a new concrete overlay on the Woody Seat Avenue C bridge, engineers concluded the layer is structurally sound and the contractor will apply a multi‑layer polymer (epoxy) overlay at no cost to the city; the city negotiated a two‑year warranty and scheduled night work to meet material temperature specifications.
Hutchinson — City engineers and the contractor proposed a multi‑layer polymer (epoxy) overlay to fix an improperly finished concrete bridge overlay on Woody Seat Avenue C, after testing and aggressive shop blasting indicated the underlying concrete is sound but the driving surface was improperly finished.
City Engineer Evan Patterson said the construction inspector identified surface defects May 21. The contractor (Wildcat) proposed a crack sealer product but engineers and industry representatives found it inappropriate for the condition. Structural engineer Brad Shores and city staff reviewed options — including milling and repouring, which carries schedule risk — and recommended a polymer overlay that adds a protective wearing layer and can be applied at no added cost to the city.
Shores said acoustic sounding and a shop blast showed no delaminations beneath the overlay. “We believe it is a sound overlay that looks like crap,” he said, adding that the epoxy layer will provide an additional protective surface. Wildcat will apply the epoxy under strict temperature, moisture and surface‑roughness controls; some work was scheduled for overnight to meet material specifications.
The city said the change carries an improved warranty package: an initial two‑year full warranty with the option of an additional year for latent defects, covering two winter cycles that are most likely to reveal freeze‑thaw related failures. Staff said that if future localized failures occur, patching or reapplication costs will be lower than milling and replacing the concrete overlay.
City public‑works and engineering staff will maintain night inspection coverage and monitor the manufacturer’s adhesion tests during application; the project remains on schedule for completion this month if material conditions permit.
