Three of New Jersey’s premier general contractors (J. Fletcher Creamer & Son, Inc., Joseph M. Sanzari, Inc. and Railroad Construction Co., Inc.) joined together to form a tri-venture, Creamer-Sanzari-Railroad-A Tri-Venture, tasked with constructing a major new transportation hub serving MetLife Stadium and the Meadowlands Sports and Entertainment Complex. This hub created direct access to the Complex from all major railways in New Jersey and New York.

Across a span of two miles an all new railroad system was constructed connecting the Meadowlands station to the existing NJ Transit rail line. This system included over five miles of new track, 13 new concrete-tie turnouts, all required wayside signaling and grade crossing protection. Because the extension crosses Berry’s Creek, 3,500 FT of elevated structure was required, supported by over 1,000 pipe piles. The balance of the extension was built on surcharged fill.

A new two-story train station was constructed with access to two platforms and three tracks. This station can accommodate up to 10,000 riders per hour allowing for the easy flow of foot traffic to and from the Complex. This modern facility now makes mass transit an attractive alternative for traveling to and from sporting events, concerts and attractions at the Meadowlands.

• All work was performed in an operating rail yard, adjacent to active tracks

This new group of buildings was constructed for Metro-North Railroad Harmon Shop. Facility elements included reinforced concrete pile caps, grade beams and foundations, concrete slab construction with super flat floor tolerances, structural steel fabrication and erection, insulated architectural precast concrete panels with tinted and acid-etched finish, three-coat Kynar insulated metal panels, SBS modified bituminous membrane roofing, skylights, translucent and tinted windows and curtain walls. Interior work included installation of drywall, acoustical tile ceilings, VCT, carpeting, ceramic tile and epoxy resin floor coatings, pallet storage rack systems, lighting, electrical, fire suppression systems including sprinklers and FM-200 clean agent systems, plumbing and automatic temperature controlled HVAC.

Work completed in Phase II prepared the site for major facilities to be constructed in Phase III. These activities included demolition of buildings, removal of 200,000 gallon, 1,000 gallon and 550 gallon fuel tanks, site clearing, new 13.2 kV power distribution, new site storm drainage (including 4 Vortechnics water quality inlets and a 11,000 SF Storm Chamber leaching field), relocation of monitoring wells, new domestic and fire water systems connecting to existing operating services, new sanitary drainage systems connecting to existing operating systems and the treatment plant, relocation and/or construction of new storage yards and structures, fencing and gates, roadway realignment, guide rail, pavement markings and paving. Construction occurred in an operating rail yard and functioning maintenance facilities. Maintenance and protection of vehicular traffic was necessary and construction was staged in order to minimally affect Metro-North operations.

RCC procured a State Pollutant Discharge Elimination System (SPDES) permit and monitored the site through a Storm Water Pollution Prevention Plan (SWPPP). Rehabilitation of the A-31 Ossining substation included demolition of electrical equipment, lead paint and asbestos abatement, building renovation, new 15 kV switchgear, mimic panel, Supervisory Control and Data Acquisition (SCADA) System and data concentrator-based Remote Terminal Unit (RTU) with local control panel.

Maintenance pit rehabilitation and a new steel drop table system was installed with new locomotive/coach car support equipment. Once again, work took plan in the operating maintenance shop. Finally, a Quality Management System Manual was developed along with a site specific Health and Safety Plan. All fundamental building systems and the substation were commissioned.

Transforming a Long Island Rail Road maintenance site, originally constructed in 1889, into a new 47,000 SF facility for the maintenance and repair of diesel locomotives.

This Design/Build project highlights multiple disciplines including building, track and utility construction plus extensive site work.

Track work consisted of 15 new turnouts and 9 new tracks plus ballasting for 1 future track. Four tracks enter into the two-level shop portion of the 47,000 SF, pre-engineered building, allowing LIRR personnel to access locomotives for repair, maintenance and cleaning.

The shop includes major industrial equipment capable of full tuck (motor) removal from trains via drop tables, deep pits and round-tables. Additionally the shop is equipped with specified welding stations, a truck washing station and two overhead gantry cranes.

Other features of the facility includes offices, locker rooms, dining facilities and storage for tools and parts. Extensive electrical, mechanical and plumbing work was performed, including dedicated Wayside (train) power stations, gas and electrical heating and waste oil lines.

Utility and sitework around the perimeter of the building included lighting, fire hydrants, oil/water separators, watermain for suppression and a large underground detention basin for runoff water from the northern track ballast and around the new building.

This project was completed by RCC / AMCC – A Joint Venture and the lead designer was AECOM.

RCC has led the $108 million, Design/Build Mid-Suffolk Yard project since 2018. This project highlights RCC’s capabilities in a variety of disciplines including electrical, building, utility, track and sitework.

Extensive electrical underground ductbank systems were created to support the construction of two new AC power and DC traction power electrical substations, yard lighting, communication and security systems. Work on the new 32,000 SF, two-story Employee Welfare Building included a 40,000 CY excavation, installation of sanitary and drainage systems, retaining walls, new service roads and walkways plus 3,000 LF of water and fire mains and new gas service lines. The existing employee facility was demolished after employees moved into the new building.

More than 14,000 LF of track was installed in 11 new storage tracks. Various utility sheds, switch tender/drill crew sheds, hazmat and material storage facilities and a new guard booth were also constructed.

The Engineer used for this Design/Build project was HNTB Corporation.