Since May 2014, Railroad Construction Co., Inc. has been working on the civil portion of the Southern Reinforcing Project Segments 8, 10 and 11 for PSE&G. By adding two new 230kV overhead transmission circuits and three new 230kV underground circuits in the South Jersey area, Public Service will increase its electric capacity and transfer capabilities to area businesses and residents, providing better power quality, increasing reliability and reducing transmission system congestion.
A total of fifty-five new overhead transmission tower foundations were constructed. Using a 55-ton excavator with drivehead attachment, 692 12” diameter helical piles were driven 36’ into the ground. Each structure contained between eight and twenty piles (depending on the design of the transmission poles). The foundations were formed and poured with anchor bolt cages cast into the concrete. Due to the accelerated schedule two crews worked simultaneously across the 3.5 mile jobsite.
The original design called for the piles to be capped with steel. At our suggestion, working closely with PSE&G’s engineering team, we were able to redesign the caps using concrete instead. This resulted in a substantial cost savings for the Owner.
Many of the new foundation sites were largely inaccessible requiring the construction of temporary stone access roads and “lay down” areas prior to the start of work. These areas were constructed mainly of stone with filter fabric. However, in environmentally sensitive areas, timber mats were used. (Railroad Construction will remove these access areas once the tower erection is completed by others.)
In addition, much of the job took place next to active Conrail tracks requiring extra safety precautions and coordination with the railroad and a flagman. The final job tally included 10,500 tons of DGA, over 350 mats for access roads and laydown areas, 634 piles totaling nearly 32,000 LF, 200,000 LBS of rebar and 1,200 CY of concrete.
We would like to thank PSE&G, Burns & McDonnell, Power Engineers and Kenny Construction for their support throughout the project. We also thank our subcontractors and vendors Mueser Rutledge, Cyntech, RCC Fabricators, Joric Electric, Phoenix Rebar, RE Pierson, JM Ahle and Trap Rock.