Roseville Tunnel Rehabilitation
Andover, New Jersey
2025 ACI NJ Project Award | Rehabilitation and Restoration
Merit Award Winner of the 62nd Annual NJ Concrete Awards, the Roseville Tunnel is a 997-foot long hard-rock blasted tunnel built in the early 1900’s. Rail service was discontinued and the track returned back to nature. Rail service is expected to begin again in 2026. This project is intended to modernize the tunnel.
Approximately 2,000 cubic yards of macro-fiber reinforced concrete, and 3,000 cubic yards of micro-silica modified shotcrete were placed in the walls and arch of the tunnel to complete the initial tunnel liner.
Access was the greatest challenge to delivering the material. This project started in late fall and was completed in early winter. At times the concrete was delivered in sub-freezing conditions. This phase of the project is not the final face of concrete – this scope is the structural aspect which will be hidden away below additional layers of concrete and materials.
The smoothness criteria was set for one inch of variation in a 10-foot area. In many locations, shotcrete was applied over 8” thick! Extremely high tensile strengths and first-break considerations were specified. Tests like ASTM C1140 and C1604 were specified by the engineer.
Location: Byram Township, New Jersey
Prime Contractor: Schiavone Construction Co. LLC
Owner: NJ Transit