Sun Logistics, LP 9 – Design/Build Ship Dock & Fire Water Structure – Marcus Hook, PA

Commerce teamed up with ST Hudson Engineers for this Design/Build project at the Marcus Hook Industrial Complex.  The project entailed several phases including:

Rehabilitation/Construction of Docks 1A and 1B:
This phase, valued at $50 million and spanning two years, required the complete demolition of the existing roadway and pipe way, loading platform, and two existing mooring dolphins with walkways. Rehabilitation included installing additional driven piles and structural steel to accept prefabricated pipe modules. The new roadway/pipe way and the new loading platform were constructed with new driven piles, precast pile caps, and precast roadway beams. At the loading platform, two breasting dolphins and a crane tower foundation were also constructed. Along with the roadway/pipe way and loading platform, two breasting cells were demolished, re-rung with steel sheet pile, and capped. Six mooring dolphins were also constructed along with walkways. All work was completed on schedule and within budget.

Installation of New Fire Water Intake Structure:
This phase, valued at $20 million and spanning 1.5 years, was needed to upgrade the fire water system while maintaining the existing system to ensure fire suppression water was available to entire facility during construction. Demolition of the existing dockspace, which included the concrete seawall and pile support low deck, was necessary to make way for the new structure.  To ensure work would occur in dry conditions, a 4-sided combiwall cofferdam, 35 feet deep was installed around the perimeter of the structure. The cofferdam was 50 feet wide x 100 feet long. To increase the speed of the internal concrete construction, a precast set of concrete modules were fabricated off-site and then floated to the work area for segmental installation inside the cofferdam. A concrete cap was also fabricated of precast and set on driven pipe piles. The remaining structural and topping slab concrete were cast-in-place. MEP and structural steel components were set and assembled on or through embedded hardware in the concrete. All work was completed on schedule and within budget.