James River Crossing

Conveying Wastewater from Newport News to Suffolk, Virginia, Across the James River

Newport News, Virginia

The James River Crossing design-build project supports Hampton Roads Sanitation District’s (HRSD) Sustainable Water Initiative for Tomorrow (SWIFT) program. Photo courtesy of Garney Construction.

In May 2024, a major milestone was reached as the installation of over 5,700 linear feet of 42-inch dimension ratio 11 high-density polyethylene was completed using horizontal directional drilling. Photo courtesy of Garney Construction.

This installation is the current single longest high-density polyethylene pipe installation of this diameter worldwide using horizontal directional drilling. Photo courtesy of Garney Construction.

Our firm has been responsible for the engineering analysis of the force main installation while working closely with key engineering partners. Photo courtesy of Garney Construction.

The Hampton Roads Sanitation District (HRSD) has undertaken the Sustainable Water Initiative for Tomorrow (SWIFT) program to improve water quality within the Chesapeake Bay. The program is funded by state and federal grants and low-interest loans, including the Virginia Clean Water Revolving Loan Fund (VCWRLF), Water Quality Improvement Fund (WQIF), and Water Infrastructure Finance and Innovation Act (WIFIA). A key project which supports HRSD in its SWIFT program goals is the design, construction, and commissioning of a new section of transmission sewer force main from the Boat Harbor Pump Station in Newport News, Virginia, to the Nansemond Treatment Plant in Suffolk, across the James River. The project aims to reduce nutrient loading to the Chesapeake Bay, replenish the Potomac Aquifer, and combat sea level rise through reduction of ground subsidence throughout the region.

The marine section of the force main is being constructed under the navigation channel and along the bed of the James River and is the critical link in this new system. The scope of work includes the installation of 24,400 linear feet (LF) of 42-inch to 54-inch high-density polyethylene (HDPE) sewer force main under and across the James River. Sections of the pipeline include 1,300 LF of 48-inch HDPE force main on the Newport News landfall, 5,700 LF of 42-inch HDPE directional drill with a land-to-water crossing of the Newport News Ship Channel, and 17,600 LF of 48-inch HDPE subaqueous pipe installation to the south landfall in Suffolk. The scope also includes installation of a 48-inch plug valve in an existing vault. In May 2024, a major milestone was reached as the installation of over 5,700 linear feet of 42-inch dimension ratio 11 HDPE was completed using horizontal directional drilling (HDD). The installation was necessary to cross under the Newport News shipping channel, which is the sixth busiest port in the U.S., without disturbance. This installation is the current single longest HDPE pipe installation of this diameter worldwide using HDD. The next phase of the project will include a marine open cut installation for the remaining 3.5 miles.

24,400

feet of sewer force main

42-to-54

inch-diameter high-density polyethylene sewer force main pipe

As the lead designer, our firm is responsible for managing the permitting and design of the project. Numerous challenges throughout the design required unique technical knowledge of force main systems, pumping station design, complex hydraulics, and material analysis to properly design the project. Our team completed an engineering analysis of the force main being installed in the James River to confirm long-term stability of the pipeline.

This analysis included buckling and deflection calculations during both the construction phase and long-term operational phase, settlement modeling of the marine environment, including three-dimensional finite element models (FEM) of the system to confirm both initial and long-term settlement, and sediment transport models of the marine stockpile material to determine approximate sediment dispersion across the sensitive James River. In addition, we have supported more standard design elements such as site access roads, erosion and sediment control, structural analysis of nearby improvements, and safety reviews. We have partnered with HRSD operations staff on both the north and south shore of the project to review details, coordinate projects, and discuss long-term pipeline operation to develop the best design.

Client

Hampton Roads Sanitation District

Awards

Honorable Mention, 2024 Project of the Year Awards,

Trenchless Technology Magazine

Cost

$145 Million (design-build total)

Services

Engineering
Planning, Consulting and Advisory

Markets

Water

Regions

Southeast