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Shell Cracker Plant Transportation Improvements 2017 Transportation Forum University of Pittsburgh

April 5, 2017

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SR 18 Relocation Overview • Project Purpose & Need: – Shell constructing petrochemical facility in Beaver County – “Cracker Plant” – Site design requires large footprint between constraints (Ohio River, I-376, and SR 18) – Construction of the facility requires 6,000 on-site workers during multi-year timeframe • Description: – Relocate SR 18 by 950 feet to the south, 6200 feet total relocation – SR 18 goes from two lanes (current) to six lanes (temporary during construction), four lanes (ultimate) – Reconfigure SR 18/I-376 Interchange

SR 18 Relocation Overview • Unique Project: – Private developer 100% funded planning, design, and construction of the improvements – Construction activities for new SR 18 alignment occurred on private property - R/W transferred to PennDOT the day before before opening new SR 18 to traffic – Roadway reconfigured for decreased capacity after facility is constructed

• One of the Largest HOPs in PA: Was successful due to the communication, coordination, and partnership between Shell, local, state and federal agencies, and construction contractors.

Project Team • • • • • • • •

Shell Jacobs PennDOT District 11-0 PennDOT Central Office Beaver County Potter Township Center Township Water & Sewer Authorities

• • • • • • •

Duquense Light Lindy Paving Trumbull Mascaro CSX FHWA DEP

Project success was due to the communication and coordination between the developer, local, state and federal agencies, and construction teams through planning, design, and construction.

Project Overview

Ohio River

PROPOSED PA CHEMICAL FACILITY

West Haul Bridge

East Bridge

Project Overview

West Haul Bridge

• Road/bridge necessary to cross: – Existing Route 18 – Relocated CSX Railroad – Future Shell Rail Lines

• Temporary condition – hauling operation • Permanent condition – site access road • Challenges – Compressed design schedule – Short construction duration over winter – Heavy vehicular load

West Haul Bridge

• Heavy Haul Considerations Alternatives – – – –

Prefabricated temporary haul bridge Permanent bridge At-grade crossing Conveyor belts

• Design Loads – Standard PennDOT/AASHTO Highway Loads – Caterpillar 777G (360 k GVW)

West Haul Bridge

CAT 777G (360,000 lbs GVW)

PHL-93 (72,000 lbs GVW)

West Haul Bridge

West Haul Bridge

West Haul Bridge

• P/S Concrete PA Bulb-Tee Beams 33x71.5 – – – – – –

Cost effective Low future maintenance Quick fabrication turn-around time 10 beams @ 6.5’ Spacing 10,000 psi concrete 0.6” diameter strands

West Haul Bridge

• Reinforced Concrete Deck & Approach Slabs – – – –

Special designs for heavier loads 12” thick concrete deck with future LMC overlay 30” thick approach slabs Steel plate over neoprene strip seal

West Haul Bridge

• Pile Stub Abutments with MSE Walls (BC-799M) – – – –

Cost effective & quick construction Minimize concrete pours in winter Integral CIP concrete crash wall for adjacent railroad Predrilling to eliminate pile downdrag

• Wall Piers – Simple construction – Integral crash wall for adjacent railroad

West Haul Bridge – Construction

• Request to run larger equipment across bridge – CAT 785C • 550 k GVW (compared to 360 k GVW for CAT 777G) • 50% heavier than CAT 777G design • Bridge did not rate – Various additional equipment loads evaluated – Signs installed at bridge approaches • One vehicle in each direction at a time (200’ spacing) • Limit equipment on bridge & speed to 15 MPH

West Haul Bridge – Construction

• Future Pipe Rack – Additional 1.5 k/ft – Evaluate for final condition – Design modifications to accommodate

SR 18 Relocation Overview

PostConstruction During Construction

Planning & Design

• Multiple Alternatives were analyzed and a Preferred Alternative was chosen that met Shell’s project goals and PennDOT/FHWA requirements.

• A Traffic Impact Study (TIS) was needed for a new development.

• A Point of Access (POA) Study was needed to modify access to the interstate.

• Highway Occupancy Permits (HOPs) were needed for all work in existing and future R/W.

Planning & Design

• Multiple Alternatives were analyzed and a Preferred Alternative was chosen that met Shell’s project goals and PennDOT/FHWA requirements.

• A Traffic Impact Study (TIS) was needed for a new development.

• A Point of Access (POA) Study was needed to modify access to the interstate.

• Highway Occupancy Permits (HOPs) were needed for all work in existing and future R/W.

• All on an accelerated schedule.

Planning and Design (TIS, POA & HOP)

Construction Substantially Complete

2015

Traffic relocated to new SR 18

HOP Approved, Permit Issued SR 18/I-376 Construction Begins

2014

Various coordination meetings & interim submissions

POA Approved

Alternatives Analysis

TIS Approved – Detailed Design Begins

2013

Various coordination meetings & interim submissions

Preferred Alternative Selected

Coordination with Agencies early in the process

Needs Assessment & Project Scope

Project Timeline 2016

Construction

Coordination between Shell & Jacobs

Coordination between Shell, Jacobs, PennDOT, County, Townships

Coordination between Shell, Jacobs, PennDOT & contractors

Planning & Design

• Full Roadway Construction Plan set – Roadway, Signing & Striping, Traffic Signals, Highway Lighting, Water & Sewer, MPT, E&S – Followed PennDOT standards and project development process, except bidding & contractor selection

• Approximately 20 other minor HOPs – Demonstrated PennDOT’s willingness to work with Shell’s evolving needs and schedule requirements • Heavy Haul Crossing • Poorhouse Run Culvert • West Haul Bridge • Various other utility and driveway accesses

Heavy Haul Crossing • Needed to commence hauling 7M CY of excavation from the one side of SR 18 to the other • Required coordination between Shell, PennDOT, Potter Township Police Department, Jacobs & Contractors

Heavy Haul Crossing • No incidents during daytime or nighttime operations

Poorhouse Run Culvert • Stream enclosure, 10’x8’ box culvert, 2850’ long, under SR 18 and site • HOP for temporary roadway to install culvert under SR 18 • Majority on Shell’s property; one section in PennDOT’s ROW to be maintained by PennDOT

Poorhouse Run Culvert

Poorhouse Run Culvert

Poorhouse Run Culvert

SR 18 Relocation

SR 18 Relocation

SR 18 Relocation

West Haul Bridge

SR 18 Relocation

Heavy Haul Crossing

West Haul Bridge

SR 18 & I-376 Interchange

ROW & Ownership Transfer

• Timing and coordination were critical – Traffic could not be shifted until PennDOT owns the road – Signature & recording of R/W Plans were tied to construction schedule

ROW & Ownership Transfer

August 12, 2016 36

Shell’s decision to build is “biggest investment in Pennsylvania since World War II” - Governor Tom Wolf, June 7, 2016

Thank you!

Questions / Answers

Steve Cunningham, PE, PTOE David Phelan, PE

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