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 rehabilitation project addressed 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. In addition, subsurface voids were filled and stabilized as part of the project; the Commission's New Jersey segment of I-78 is in an area where subsurface limestone geological formations are prone to producing sinkholes.

The rehabilitation project was performed with a goal of preventing major repairs for the next 15 years. The work included rehabilitation of the concrete roadway pavement, rehabilitation of the bridge decks, and various highway feature upgrades along the corridor.

To carry out the project, a variety of techniques were employed to give the busy roadway a better foundation and ride, including polyurethane grout injection and concrete slurry grouting.   "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.  When the concrete slab rehabilitation work is completed, the entire surface will be given a 7-inch asphalt overlay.  The project also included ramp rehabilitation work at Exit 3 -- the Still Valley Interchange.

"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."

Rehabilitation of an additional 2.25 miles of I-78 within the Commission's jurisdiction on the Pennsylvania side of the Delaware River will take place under a separate contract within the next several years.

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.

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

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