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Civil & Marine, Energy & Renewables, Heavy Industrial

Shell Pennsylvania Petrochemicals Complex

Monaca, Pennsylvania

Supporting a new global-scale petrochemical processing plant on the banks of the Ohio River

Market

Civil & Marine

Energy & Renewables

Heavy Industrial

Key Services

Construction

Self-Perform

Strategic Partnerships

Delivery Method
General Contracting (GC)
Self Perform %
90

The challenge

Constructing a riverfront docking and bulkhead facility on the Ohio River in preparation for Shell’s new ethane cracker and polyethylene complex required excavation of more than 2 million cubic yards of earth on a 540-acre site. At peak excavation, our crews removed roughly 45,000 cubic yards per week. The project required dealing with fluctuating water levels and significant weather challenges, as well as coordinating the delivery of prefabricated materials and equipment that were too large for truck delivery. Additionally, ensuring environmental protection and maintaining water quality during construction were essential due to the project’s location on the Ohio River.

Alberici built a massive riverfront docking and bulkhead facility on the Ohio River that enabled receiving and sub-assembly during construction of the main petrochemical complex. Alberici’s scope of work included construction of a 600-foot-long load-on/load-off dock, 210-foot-long roll-on/roll-off dock, foundations for two wastewater treatment clarifiers, 24 mooring dolphins, and demolition of existing marine facilities.

Key Facts

810,000 SF river dock


24 mooring dolphins


150,000 cubic yard dredging


Shell Corporation Contractor of the Quarter

Challenge met

Alberici deployed a carefully coordinated marine fleet, including barge-mounted cranes and push boats to handle the large materials. We self-performed a significant portion of the work from land to accelerate the schedule and control costs. Alberici addressed challenges through meticulous planning and extensive experience in constructing similar facilities on major inland waterways.

To protect the environment, we implemented measures such as using a floating turbidity boom to maintain water quality and creating a shallow-water fish habitat with riprap. We worked closely with Shell, design teams, and permitting authorities to ensure environmental preservation.

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