Paulsboro Marine Terminal - Stage 1 Rail & East Parcel Development

Paulsboro, NJ

Stage 1 Rail & East Parcel Development: Contract PMT-013 is the first 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-013 is the first 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 County Improvement 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, electrical work, and the railroad track work.

Project Highlights

Construction Highlights

  • 70,000 cubic yards of fill material was imported, placed, compacted and graded to raise the elevation of the 40 Acre work area. KCC’s GPS-guidance system helped to expedite the earthwork.
  • Concurrent with the earthwork, KCC’s crews commenced the construction of the underground utilities to create the new site infrastructure.
  • In addition to sanitary sewer and storm drainage improvements, KCC’s crews constructed 5,300 LF of new 8”, 10” & 12” diameter water mains and fire lines along with 13 new Fire Hydrants. In conjunction with the underground utility work, KCC installed over 1,100 LF of 16”, 18” & 20” diameter steel casing pipes at 22 locations throughout the site where the new underground utilities crossed under the new railroad tracks. All steel casing pipes were installed in accordance with Conrail Pipe Occupancy Standards.
  • KCC constructed an extensive concrete-encased, underground power and communications duct bank system for the new marine terminal that included the installation of over 50,000 LF of 2”, 4” & 5” Schedule 40 PVC conduits along with 62 precast concrete electrical and communications manholes and handholes that weighed up to 16 Tons each and required grounding.
  • Since the site was previously used as a petro-chemical production facility, there were several underground areaswhere contaminated soil and groundwater could have been encountered during the trenching and excavationoperations.
  • KCC prepared a site-specific Health & Safety Plan (HASP) and provided full-time Health & Safety oversight duringthe entire project to assure compliance with the HASP, and to ensure that the workers were provided with the appropriate PPE and monitoring.
  • After the site utilities were installed, KCC focused on the construction of the surface improvements, which included importing, placement and grading of 100,000 Tons of Dense Graded Aggregate Surface Course, spread to a thickness of 10” over the 40-Acre work area.
  • Because the new marine terminal is an intermodal facility, the project also required the construction of 18,000 LFof new, continuously welded railroad tracks with wood ties, along with associated turn-outs and switches, nine new precast concrete grade crossings, and a tie-in to the nearby Conrail tracks. The new tracks required the importing, placement and grading of over 30,000 Tons of Sub-ballast and Ballast stone that met Conrail specifications.
  • To serve the new Rubber Tire Gantry (RTG) Cranes at the heart of the new terminal, KCC constructed a pair of parallel, reinforced concrete RTG Runways that flanked the four-yard tracks. In order to construct the 2,500 LF of RTG Runways, KCC’s crews formed, placed, finished and cured approximately 530 CY of 4,000 psi concrete.
  • An entire compressed air system was installed for the new rail system consisting of a Pre-Packaged Air Compressor Station and almost 3,000 LF of 3” diameter HDPE air lines distributed to 14 compressed air stations along the new railroad tracks.
  • 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.


Special Acknowledgement

After KCC had been working on the Paulsboro Marine Terminal project for several months the on-site Construction Manager wrote the following unsolicited endorsement of KCC’s Project Team:

“In the past 4 months working with the KCC team on the Paulsboro Marine Terminal, it is very apparent Kyle Conti Construction is a first-class professional organization. I find the entire KCC team, from laborer to superintendent, to be safety conscientious, operationally efficient and quality minded. This spirit comes from the leadership of Kyle Conti who I find extremely passionate in the manner in which he runs his construction company.”

KCC also appreciated the opportunity of working with the GCIA, the Engineer of Record - CH2M, and the Construction Manager – AECOM, as a team on this important new marine terminal for the GCIA / SJPC.