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Herzog Joint Venture Awarded Amtrak Sawtooth Bridges Replacement Project

Amtrak recently awarded the $2B Sawtooth Bridges Replacement Project preconstruction services contract to the Skanska-Walsh-Herzog joint venture.

 

A view of the current Sawtooth Bridges. Two staggered viaduct structures give the bridges their sawtooth look.

This project will see the demolition and replacement of the Sawtooth Bridges in Kearny, New Jersey between Newark Penn Station and Secaucus Junction.

During this state-of-good-repair project, Herzog and its JV partners will construct three new rail bridges and two new tracks, doubling track capacity. The new bridge structures will improve commuter and intercity passenger rail operations in the busiest section of the Northeast Corridor (NEC).

The Sawtooth Bridges were originally constructed in 1907 as a critical link in the NEC that supports more than 400 daily trains operated by Amtrak and NJ TRANSIT over tracks used by NJ TRANSIT, PATH, and Conrail freight trains in a 1.9-mile corridor. The two staggered viaduct structures (which gives the bridges their sawtooth look) will be demolished.

The original bridges will be replaced with three new rail bridges. Bridge #1 will realign NJ TRANSIT’s Morris and Essex Track 5 further north to create space for two additional NEC tracks. Bridge #2 will be built adjacent to the existing Amtrak Sawtooth bridges and increase NEC capacity with two new tracks. Bridge #3 will completely replace the two sawtooth bridge structures that currently carry the two existing NEC tracks. These tracks will be replaced with newly constructed tracks. The superstructure of bridges #2 and #3 will be supported by a mix of micropiles and deep foundations (both drilled and driven). The superstructure will have typical span lengths of 50 feet and cross-girders up to 110 feet long. Both bridges will carry two tracks each for a total of four tracks along this segment of the NEC.

Additional work includes significant modifications to approximately 2,500 linear feet of overhead catenary system (OCS), temporary shoofly tracks, drainage structures, 10 retaining wall sections, and crash walls.

The project site features challenges that Herzog and its JV partners will need to overcome. The 1.9-mile corridor is congested with train traffic that results in limited access points for crews and equipment. Extensive coordination will be required with Amtrak, NJ TRANSIT, PATH, Conrail, and various third-party utilities. Work will be conducted in a live track environment that preserves train operations during construction.

“Herzog is honored to partner with Skanska and Walsh to build this historic project for Amtrak,” Scott Norman, Executive Vice President of Construction, National Construction, said. “We look forward to partnering with all involved to make this a successful project.”

The project is being delivered with the Construction Manager at Risk (CMAR) delivery method. Final design of the new bridges is underway concurrent with a number of preconstruction services being performed by the Skanska-Walsh-Herzog joint venture to prepare the project for the construction phase. Major construction is expected to begin in 2026. The expected date for project completion is 2034.