I-78 NJ Roadway Rehabilitation

The Delaware River Joint Toll Bridge Commission began rehabilitation project work along its 4.2 mile New Jersey portion of I-78 in October 2007.  Engineers deemed the project to be substantially completed on September 25, 2009.

The Commission's I-78 jurisdiction in the state consists of a six-lane roadway constructed of reinforced concrete, extending from the Delaware River bridge to the Still Valley Interchange (Exit 3).  This roadway segment encompassing four Warren County municipalities -- Phillipsburg, Pohatcong, Alpha and Greenwich Township -- origninally opened to traffic on November 21, 1989. 

The project was undertaken to address premature cracking of the concrete roadway slabs and settlement of the roadway due to the heavy truck traffic that uses the I-78 corridor every day.

A variety of techniques were employed to give the busy roadway a better foundation and ride, including polyurethane grout injection and concrete slurry grouting. (The Commission's New Jersey I-78 segment is in a geological zone where subsurface limestone formations are prone to producing sinkholes.)

"Crack stitching" also was utilized at roughly 2,200 locations as part of the roadway rehabilitation effort. In some worst-case areas of roadway deterioration, existing concrete pavement was removed and replaced with concrete slabs in a process known as full-depth replacement.

A series of other improvements were achieved under the project, including the installation of new pavement, repairs to various overpasses and secondary bridge structures, and the placement of safety upgrades, such as new striping and guiderails.

The project put the roadway in a state of condition where it should not require any sustained lane closures for at least 15 years. The work also enhanced the Commission's ability to handle an anticipated rise in truck traffic due to increased Port of New York and New Jersey shipments after the Panama Canal widening project is completed in 2015. Over 2 million trucks travel along I-78 westbound each year, making it one of the nation's most heavily traveled truck routes.

The project's completion came at an optimum time - slightly a month before the 20^th anniversary of the opening of the I-78 Toll Bridge and related facilities. The Commission's I-78 segments in New Jersey and Pennsylvania opened to traffic on November 21, 1989, constituting the final link in the 144-mile interstate highway between Holland Tunnel to the east and Harrisburg, Pa. to the west.

"While this project may have looked like a simple resurfacing project to many passing motorists, it was a much-more involved undertaking due to the unique geology of the area traversed by this major east-west highway," said Frank G. McCartney, the DRJTBC's executive director.  "The result of all the work is a much smoother and safer ride for the driving public."

The total program cost for the rehabilitation of the Commission's New Jersey I-78 segment was $57.6 million.  The construction contractor was Tilcon of Wharton, N.J.  The project reached substantial completed as originally projected -- early fall.

During the construction phase, the Commission maintained a toll-free project hotline, this Web page, and issued frequent press updates and alerts.

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