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Federal Creosote Superfund Site

Project Name Federal Creosote Superfund Site
Location Manville, New Jersey
Contract Value $142,000,000 (Combination Firm Fixed Price and Cost Reimbursable)
Period of Performance November 2000 - April 2007
Role Prime Contractor
Significant Project Features Project Gallery History & Location Details Project Description Health & Safety Overview

Significant Project Features

  • Excavation, characterization, transportation and disposal of 450,000 cy of contaminated material from 2 lagoons and 100 residential and commercial properties for offsite thermal treatment or landfill disposal.
  • Work area and perimeter air monitoring system implemented to protect project personnel and community residents during remediation activities.
  • Design, construction, operation and maintenance of a 450 GPM groundwater treatment and excavation dewatering system.
  • Design and installation of a soldier pile, steel sheeting, and lagging system to protect an active railroad during deep excavations.
  • Multi-media sampling and chemical analysis of air, soils, and water.

History & Location Details

The Federal Creosote Superfund Site is a 50+ acre site located in the Borough of Manville, New Jersey. From the 1910s to 1957, the American/Federal Creosote Wood Treatment facility treated wood with creosote. The facility used a system of lagoons and canals to contain liquid waste from the creosote operation in the north central (Lagoon A and Canal A) and southeast (Lagoon B and Canal B) sections of the site, as well as a centrally located lumber yard for untreated wood and a drip area for treated wood products.

In 1962, construction began on the Claremont Development, a 137-property residential community. The former lagoons and canals were filled and the residential development was constructed on top of the former lagoons, canals, drip areas, and lumber storage areas. The waste from the site was not removed prior to construction of the development. Later, the Rustic Mall was constructed and located on the former western portion of the site. USEPA took soil samples in the Spring of 1998 at numerous residential properties within the development. Analytical results indicated the presence of creosote, as well as other compounds, at elevated levels. The site was added to the NPL in 1999.

Sevenson was awarded multiple task orders to remediate the Federal Creosote Superfund Site under its USEPA Region II Pre-placed Remedial Action Contract (PRAC) through the U.S. Army Corps of Engineers, Kansas City District. Due to the nature of the project, remediation activities were executed with care to minimize disruption to the residents and emissions of creosote odor in the surrounding area.

Project Description

Key areas of remediation included:

  • Wastewater Treatment
    Sevenson designed, operated, and maintained a temporary groundwater treatment and dewatering system to dewater excavation areas. A series of 80 dewatering wells and dual-containment force mains were installed in and around the lagoon areas. Over 80 M gallons of construction water was extracted and treated using oil/water separation, organo-clay and bag filtration, and liquid phase carbon polishing prior to surface discharge to the Millstone River under a B4B Qualifying Permit.
  • Excavation Operations
    Deep excavation of the lagoon area (up to 34 feet BGS) required the design and installation of soldier pile, steel sheeting and wood lagging system. The lagging system protected the active railroad that bounds the Claremont Development; the sheeting protected non-rail sides of the excavations. Working in Level C or D (modified) PPE and using conventional construction equipment, contaminated soil was excavated and stockpiled according to classification (thermal, Subtitle C, or Subtitle D) prior to loading and offsite transportation. Soils were transported in lined dump trailers to licensed/approved disposal facilities.Primary excavation limits at each property was based on cut lines derived from GeoProbe® characterizations. Secondary excavation was based on confirmatory grid sampling as outlined in Sevenson’s approved SAP. Imported backfill was tested prior to acceptance at the site. As the fill was placed and compacted, Sevenson’s QC conducted Troxler compaction testing to ensure the structural stability of restored areas.
  • Perimeter Air Monitoring
    Sevenson developed a Perimeter Air Monitoring Program for airborne contaminants. This program included real time monitoring for both particulates and volatile organic compounds and documentation monitoring using EPA methods T0-13, T0-14 and PM-10. A unique feature of the real time monitoring was the use of telemetry to transmit the VOC results to a central command. This enabled Sevenson to implement odor and/or vapor control programs quickly, when required. Due to the close proximity of the residential community, odor control measures (a foaming system was used for extended periods of exposure to odors and a misting system was used in conjunction with foaming during excavation/loadout operations, as necessary) were implemented to control creosote emissions during the excavation work.
  • Site Restoration
    Excavation areas were backfilled with compacted common fill to rough grade elevations. Coordination with local utility companies was required to replace buried utility mains, manhole structures and service laterals to each property, as well as overhead utility poles and lines. Concrete structures, (i.e. curb, gutter, sidewalk, driveway, apron, and patio), demolished prior to excavation activities, were replaced. Landscaping, topsoil and sod were installed to meet or exceed preconstruction conditions.
  • Chemical Quality Management
    Sevenson managed data for 3,600 air, soil, and water samples. Electronic delivery of analytical results were provided by Sevenson’s in-house laboratory. Chemical QC inspections verified that all aspects of the approved SAP were followed and data met project requirements.
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Health & Safety Overview

Sevenson and subcontractors worked in excess of 225,000 man-hours on this site with ZERO lost-time injuries. ACOE awarded Sevenson the Commander’s Certificate of Appreciation to recognize the results of our proactive safety program.

Sevenson’s Safety Staff included one SSHO and four Safety/Air Monitoring Technicians to ensure adherence to the approved SHERP. Roughly 15% of the work was conducted in Level C PPE; the balance performed in Level D (modified) PPE.

Due to the aromatic (noxious) nature of creosote wastes, Sevenson’s odor control plan made use of several engineering controls:

  • Real-time air monitoring for VOC and respirable particulates; monthly air sampling for VOC, PAH, total particulates, and BTEX/PAH.
  • Use of foam for vapor suppression on excavation faces and stockpiles, and covering stockpiles with polyethylene sheeting.
  • Modifying excavation rates to minimize exposed surfaces.
  • Use of Triad Series 2 Vapor Suppression distribution system to dispense more fragrant aromas.

Traffic control was important from resident convenience and emergency response perspectives. Transport vehicles were covered and decontaminated prior to departing any residence or the soil loading area. Sevenson scheduled work to minimize road closure; posts detour and alternate route signage; and meets periodically with local Fire, Police, and EMS to review street closings.

Rooted in Remedial Construction
Expanded into Environmental Dredging

Remedial ConstructionEnvironmental DredgingAdditional Services

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