PSE&G Southern Reinforcing Project

• Constructed 55 concrete foundations at 35 different locations for new electrical transmission pole structures across 3.5 miles
• Drove 692 12” diameter helical piles, each 36’ deep
• Redesigned proposed steel pile caps and replaced with concrete caps resulting in substantial savings for Owner
• Created stone access roads and “lay down” areas leading to work locations

 Challenges:

• Numerous jobsites with limited accessibility
• Accelerated schedule requiring two separate work crews working simultaneously to meet deadline
• Work performed next to active tracks

Project Description:

Starting in 1903, PSE&G is New Jersey’s oldest and largest publicly owned utility company.  It serves nearly three-quarters of New Jersey’s population across 2,600 square miles. 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 local businesses and residents, providing better power quality and reducing transmission system congestion.

Using a 55 ton excavator with drivehead attachment, 692, 12” diameter helical piles were driven 36’ deep into the ground to support the new overhead transmission towers.  Each structure contained between eight and twenty piles depending on the design of the transmission poles.  Fifty-five separate 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 job site.  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.  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 original design called for the piles to be capped with steel.  At our suggestion, working closely with PSEG’s engineering team, we were able to redesign the caps using concrete instead.  This resulted in a substantial cost savings for the Owner.

This project is a part of PSE&G’s ongoing commitment to improving electrical capacity and reliability for their customers.