About an hour northwest of Newark, New Jersey, is the historic Roseville Tunnel, situated in Byram Township, Sussex County. The Roseville Tunnel Rehabilitation Project is a design-build project and is part of NJ TRANSIT’s (NJT) Lackawanna Cut-off Restoration. The Lackawanna Cut-off—a historic rail line in New Jersey and Pennsylvania—was originally built by the Delaware, Lackawanna & Western Railroad in the early 1900s. It runs from Port Morris Junction in New Jersey to Slateford, Pennsylvania. NJT’s restoration will extend passenger rail service from Port Morris, New Jersey, to a new rail station in Andover, New Jersey.
The horseshoe-shaped Roseville Tunnel was completed in 1911. This rock tunnel was originally double-tracked and operated for freight and passenger transport from 1911 to 1979. It is mostly unlined, but has approximately 140 feet of concrete liner where a regional fault runs through the tunnel. The design-build team is led by Schiavone Construction Company LLC, and Delve Underground is the lead designer. Eight specialized subconsultants are also on the design team.
Notice to Proceed was received from NJT in September 2022. Delve Underground designed the rock excavation, slope protection, concrete repairs, tunnel linings, and waterproofing, as well as managed the design team and the design services during construction. The design team had 180 calendar days to prepare the 60% design documents and 325 days to prepare the 100% design documents.
The scope of work for the project
Rock excavation by blasting at the west portal of the tunnel to shorten it by at least 15 feet, from 1,014 feet to just under 1,000 feet long.
Slope protection and stabilization on both the west and east rock cut approaches to the tunnel, including removal of loose rock, vegetation and tree removal, installation of cable mesh and netting, rock bolting, and construction of adequate catchment areas at the base of the slopes.
Repair of the existing concrete tunnel liner, which includes grouting the void space behind it and repairing surface defects and concrete spalls.
Removal of loose rock and rock bolting in the unlined sections of the tunnel.
Installation of a shotcrete initial lining in the unlined sections.
Installation of a PVC waterproofing membrane to provide a continuous tunnel waterproofing system through the tunnel.
Installation of a shotcrete final lining throughout the entire tunnel.
Installation of CCTV cameras at both portals.
Installation of communications systems in the tunnel and a communications tower above the tunnel to receive radio signals.
Installation of a lighted path inside the tunnel for employee and first responder access and evacuation purposes, extending 50 feet beyond both portals.
Installation of permanent electrical power to the tunnel.
Restoration of 8,000 feet of track roadbed to 3 inches below the bottom of existing ties, including cutting, clearing, and disposal of all brush, trees, vegetative matter, and debris; roadbed excavation; restoring the drainage system; and initial ballast placement.
Obtaining selected permits required for construction.
Rock slope protection and stabilization
Featured image: Application of shotcrete final liner over the PVC waterproofing membrane
