Large RCP Pipe Used To Reconstruct Stormwater Outfalls For Post-Hurricane Sandy Resiliency Project In New Jersey

As part of the Christie Administration’s post-Hurricane Sandy storm resiliency effort and part of the Sandy Hook to Barnegat Inlet Beach Erosion Control Project, Oldcastle Precast was contracted to supply 2,704 feet of reinforced concrete pipe (RCP) to extend several stormwater outfalls into the ocean in the area of Loch Arbour and Deal in Monmouth County, NJ.

The overall project, pumping 1.4 million cubic yards of sand on 1.6 miles of beach in Elberon and Deal, as well as the modification to six existing stormwater outfalls and two existing groins, coastal protection structures extending from the beach into the ocean, is part of the Christie Administration’s comprehensive resiliency plan to reduce risk from storm damage on the New Jersey shore. In the aftermath of Hurricane Sandy, these coastal protection structures will provide additional beach erosion control and storm risk reduction to this coastal area.

Overall, the Christie Administration, in partnership with the U.S. Army Corps of Engineers, awarded a contract of approximately $90M to Manson Construction Company of Seattle, WA to reconstruct beaches, storm water outfalls and implement modifications to existing groins at Loch Arbour and Deal, NJ.  

As a portion of the project, Agate Construction of Oceanview, NJ was subcontracted to install extensions to the stormwater outfalls, who in turn contracted Oldcastle Precast Folsom, N.J. to design and manufacture 584 feet of 58-inch x 91-inch HE 3 (Horizontal Elliptical-Class 3) reinforced concrete pipe (RCP); 592 feet of 63-inch x 98-inch HE3 RCP; and 1,528 feet of 96-inch diameter O-ring gasketed RCP. Outfall 19 was designed to accommodate the 63-inch x 98-inch HE3 RCP. Outfall 34 was designed for the 58-inch x 91-inch HE3, and outfall 36 was designed for the 96-inch diameter RCP.

Due to the marine environment, the RCP was designed to be produced with a special concrete mix and reinforced with galvanized reinforcing wire to resist corrosion.  

“Working with the galvanized reinforced wire posed new challenges for the facility, but the team was successful at accomplishing this endeavor,” said Nike Domenico, Sales Manager for the Oldcastle Precast Mid-Atlantic Pipe Group.

Additionally, several RCP pipe units were produced as special length or skewed end pieces, so that the joints would lay precisely upon a saddle-supporting system connected to 45-foot piles driven to a depth of 40 feet. The saddle-supporting system was installed preceding the pipe installation.

The outfalls, a place where the stormwater drains or discharges, generated several challenges that had to be addressed. Primarily, marine weather conditions; high waves and wind affecting the installation of the piles and work area conditions due to high tide/low tide in the work zone; constant maintenance and dewatering of the cofferdams; precision placement of the RCP pipe; and special/custom pieces of pipe manufactured to retain straps and pipe joints to center over the centerline of pile caps. In addition, Outfalls 19, 34 and 36 supplied by Oldcastle Precast were under construction simultaneously.

Operations Manager for Oldcastle Precast Mid-Atlantic Pipe Group George Hand II remarked, “Using Reinforced Concrete Pipe on the project was a great selection of materials for this type of application and selecting Oldcastle Precast proved to be advantageous.  The project would need custom pieces sporadically throughout the project and that is our forte.  The quality RCP pipe we supplied met all specifications and the fast turnaround time reflected our commitment to the project.  The entire project was a victory from the beginning.  Having the right people in the right place in our organization allowed us to make this project a success.  It was a great accomplishment for the team and the organization.”

The restoration and repair work is funded 100 percent through the Army Corps’ Flood Control and Coastal Emergencies program. Construction is funded entirely by the federal government through the 2013 Disaster Relief Appropriations Act (PL113-2), commonly known as the Hurricane Sandy Relief Bill. Following the completion of initial construction, the project is eligible for continued periodic nourishment.

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