Paulsboro Marine Terminal - Phase 1 Site Electrical & Miscellaneous Equipment

Paulsboro, NJ

Phase 1 Site Electrical & Miscellaneous Equipment: Contract PMT-016 is the second of two back-to-back, fixed-price contracts totaling $22.5 Million that KCC successfully performed at the new 175-Acre Marine Terminal on the Delaware River in Paulsboro, NJ.


KCC was contracted by the Gloucester County Improvement Authority on its Stage 1 Rail & East Parcel Development to redevelop a former BP Refinery into a new terminal to be operated by Holt Logistics.

Contract PMT-016 is the second of two back-to-back, fixed-price contracts totaling $22.5 Million that KCC successfully performed at the new 175-Acre Marine Terminal on the Delaware River in Paulsboro, NJ. KCC worked directly for the Gloucester CountyImprovement Authority (GCIA), which is the contracting agent for the operator of the facility, the South Jersey Port Corporation.

Through a well-coordinated and organized approach, KCC was able to meet the aggressive deadlines established for both contracts. All work was completed on-time and on budget, and within an 18-month period. Most of the work was self-performed by KCC’s crews, with specialty subcontractors performing the drilling work and electrical work.

Project Highlights

Construction Highlights

  • Contract PMT-016 extended and completed the medium voltage electrical distribution infrastructure work that KCC had just constructed in their previous contract PMT-013 at the mew marine terminal site. Contract PMT-016 required the installation of an additional 40,000 LF of 2”, 4” & 5” Schedule 40 PVC conduits in concrete-encased duct banks, along with 31 precast concrete electrical and communications manholes and handholes that weighed up to 16 tons each.
  • The medium voltage power was distributed through 9 new Medium Voltage pad-mounted transformers, mini-power centers, and panelboards. The electrical work also included the furnishing, installation, termination, testing and commissioning of all high voltage, medium voltage cables and switchgear that provided power to the marine terminal and the recently constructed wharf on the Delaware River.
  • Installation of a new high voltage electrical service to provide power to the new marine terminal was coordinated with Atlantic City Electric (ACE), the local utility, which provided 12 KV power to a new 14’ wide x 66’ long Substation/Power Distribution Center (PDC) that was prefabricated at an off-site facility and transported to the site by truck in two modules. KCC prepared a lifting plan in advance and used a 110 Ton hydraulic crane and special rigging to hoist, set and assemble the 49,000-pound PDC modules on the previously prepared PDC foundations.
  • KCC designed and constructed the PDC Foundation System using custom fabricated Helical Piles that supported reinforced concrete pile caps, all of which had to be very accurately planned and installed using templates in order to accommodate multiple groups of duct banks that tied into the floor of the Substation.
  • In order to provide appropriate illumination for the nighttime operation of the completed marine terminal, an important feature of the new electrical infrastructure was the installation of 17 new, 100-foot-tall High Mast Light (HML) Towers and associated lighting controls. The HML’s were distributed throughout the new marine terminal and were designed to withstand 115 mph wind loading. KCC installed the HML’s on 48” diameter, reinforced concrete, Drilled Shafts that were constructed to depths of 25 feet below the ground surface.
  • In order to protect the newly installed light towers, transformers, and fire hydrants from potential collisions and damage from the marine terminal truck traffic, KCC installed approximately 240, concrete-filled, steel pipe bollards that were set into reinforced concrete footings and painted Safety Yellow.
  • Since the site was previously used as a petrochemical production facility, there were several underground areas where contaminated soil and groundwater could have been encountered during the trenching and excavation operations. Therefore, KCC prepared a site-specific Health & Safety Plan (HASP) and provided full-time Health & Safety oversight during the entire project to assure compliance with the HASP, and to ensure that the workers were provided with the appropriate PPE and monitoring.
  • KCC was also responsible for providing all Quality Control and Quality Assurance Testing services with an independent testing laboratory for the project to document that all work met the specified quality standards for the project.