Ports America / PNCT Phase 2

Port Newark, NJ, NJ

KCC's PNCT Phase 2 Expansion Development

Background

KCC was awarded the contract for the Phase 2 Expansion Development as part of PCNT's $500M modernization and redevelopment program that is expected to double the container terminal's capacity. Because almost all the work is located inside the operating terminal, the construction of this complex undertaking required numerous construction phases and stages. Throughout the entire project everything was closely coordinated and planned with PNCT's operations staff to ensure the uninterrupted flow of trucks and containers across the 60-Acre work area. 

 

Project Highlights

 

  • In order to provide future flood protection, a large portion of the site was filled and raised roughly 5 feet, which also required the construction of 3,600 LF of a new reinforced concrete perimeter retaining wall. 
  • An extensive amount of new storm drainage improvements and grading throughout the 60-acre site.
  • Construction and testing of 2,200 LF of new Water Mains and 15 new Fire Hydrants.
  • Throughout phase 2 over 50 acres of Milling and Paving was self-performed by KCC crews, including 160,000 Tons of Aggregate Base Course and 140,000 Tons of Port Authority approved Hot-Mix Asphalt.
  • Construction of 30,000 SY of Reinforced Concrete Pavement, 9” to 13” thick, which included the placement and finishing of approximately 10,000 CY of Port Authority approved concrete.
  • Construction of two Pre-Engineered Metal Buildings and associated reinforced concrete foundations: a 3,200 SF, 3-Lane OCR Building, and a 6-lane, 12,500 SF Roadability Structure.
  • Coordination and construction of a new 19-Lane Entry Inspection Gate complex, 14 new Exit Gates, a separate POV Entrance and Inspection Gate, a new Security Booth, along with all of the associated electronic gate arms, loop detectors, hundreds of bollards, RPM’s, RFID Readers, Kiosks & Communication Pedestals, PTZ Cameras, Laser Scanners, T-Poles, and OCR Portals. 
  • Installation of a new Customs & Border Protection Booth, along with its entrance stairs, reinforced concrete foundation, plumbing, water, power, and communications.
  • Furnish and install new site lighting, which includes 12 new 110’ & 120’ tall High Mast Light (HML) Towers, and the construction of the pile-supported reinforced concrete HML foundations.
  • Extensive Power and Communications System Improvements, including over 150,000 LF of underground conduits in concrete encased duct banks, 200 precast concrete electrical and communications manholes and handholes, and the installation of the new 13.2 KV, 480 V & 120V feeders, cables, and panelboards, and new fiber optic communications cables.
  • Construction of a new Substation on raised concrete foundations, along with a Back-Up Generator System, Transformers and Switchgear to distribute uninterrupted power to the expanded facility.
  • Relocate an existing 367 LF, 3-Tier Reefer Rack and provide a 60 LF Reefer Rack Expansion.
  • Provide 6,000 LF of new chain link perimeter security fencing and new sliding gates.
  • Install an extensive amount of thermoplastic pavement markings.
  • Demolition of the old entrance and exit gate structures, buildings and infrastructure after the completion of the new gates and new buildings.
  • Traffic control and staging of the work included temporary pavement, temporary fencing, temporary pavement markings, and over 10,000 LF of temporary and permanent precast concrete barrier curb.
  • Performance of all QA/QC Testing and Special Inspections and compliance with Port Authority requirements.

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