Replacement of AOA Guard Post

The work under this contract consists generally of the upgrading and replacement of existing hydraulic Delta barriers with electrical barriers, replacement of full guard post including the existing Delta barriers with barriers and related work at Guard Post G, Guard Post H, Guard Post I and the vicinities thereof at Newark Liberty International Airport, New Jersey.  The upgrade program consists of replacing the antiquated Delta Barriers in use throughout the airport with state of the art, high security Grab Net security systems.

Newark Airport Fuel Pipeline Modification

At one of the world’s largest and most heavily trafficked airports, Conti helps Newark Liberty maintain its aviation fueling system to industry and environmental standards.

Newark Liberty International Airport’s current fuel system was constructed in 1970 and needed repairs and upgrades to meet industry standards requiring centralized purchasing of Jet-A fuel for all users, which simplifies multi-pump fuel supply systems and piping networks. The Port Authority of New York and New Jersey called for upgrades to the current system, allowing it to function more efficiently.

Conti was responsible for Phase I of a three-phase multi-year fuel system modification program. We decommissioned the old single-wall welded steel pipe and installed approximately 29,000 linear feet of buried 22-inch double-wall steel pipe for the aviation fuel main line. The pipe included sensors for fuel leak detection and runs from the South Fuel Farm to the new Fuel Serving Area and reconnects to the Central Terminal Area. The pipeline routing will benefit a new Terminal A.

A two-position truck fill station loading rack was instructed airside next to the new Contact Water Treatment Facility (CWTF). This strategic location allows for faster fueling and results in less traffic. The new CWTF consists of three holding tanks, one reclaim tank and an oil water separator.

Modifications were also made to various components of the fueling system including valves, pumps and electrical controls. These changes will reduce both maintenance and electrical costs.

Newark Airport Runway

Hundreds of flights carrying thousands of passengers fly out of Newark each day. To meet increasing demands, the Port Authority of New York and New Jersey (PANYNJ) needed to extend its main runway closest to the terminal to accommodate pilots carrying heavier loads requiring longer takeoffs.

Conti added 1,800 linear feet on runway to the current 8,200 linear foot runway. Because the concrete needed to be as strong and long lasting as possible, the team utilized a “first ever” mix design with four aggregates instead of the conventional three.

In addition to the special concrete mixture used on the runway extension, Conti took advantage of a unique slip-form process to frame the concrete. This process called for the use of a machine to drop the concrete from a conveyor between two steel guides placed 25 feet apart. The machine slowly moved down the length of the runway pouring a depth of 16 inches of material for the first layer. After the first layer was poured, Conti crews placed reinforcing mesh on top, and then applied a second four-inch concrete layer. Another crew then utilized a “rolling bridge” to smooth and finish the surface. This project was also the first time the slip-form paving had been done at Newark Liberty International Airport.

The team executed work at an active airport in a highly urban area with minimal disruption to operations, delivering the project safely and on schedule.

Newark Airport Terminal C Bridge/Roadway

The US’s largest airport system was overwhelmed with customers.

​As part of this vital transportation hub in the Greater New York City area, Newark Liberty International Airport (EWR) sought to reduce congestion in its A and B terminals and increase ease of access for incoming travelers. To accomplish this, the Port Authority of New York and New Jersey (PANYNJ) planned a major reconstruction effort for these airport terminals, which would include the complete reconstruction of many of the terminal’s features to accommodate greater traffic and alleviate congestion.

Conti reconstructed the roadway for each terminal including a two-lane bridge leading into the Central Terminal, which effectively increased traffic flow. In addition, Conti constructed an architectural steel and glass pedestrian walkway canopy, as well as multiple toll plazas. The team performed the work in carefully planned stages to minimize inconvenience to the public during the construction phase. Conti also installed and relocated numerous utilities, including a 36-inch saltwater line, a 24-inch storm water force main, and a 12-inch water line. The team utilized a state-of-the-art steel fabrication shop to manufacture steel for the 50,000 square foot canopy structure.

In the days following the September 11, 2001 attacks, Conti worked with the Port Authority to quickly lock down the airport and maintain security measures, such as erecting traffic barriers and requiring ID badges at all times at the airport.

Conti completed this project safely and on time while working on an active airport and overcoming delays from the September 11 attacks.

JFK Airport Taxiways A & B Widening

The world’s largest commercial jet is a double-deck, wide-body, four-engine mega airplane.

Having made its first flight in 2005, the huge 853-passenger Airbus 380 required a significantly larger taxiway than other aircraft, which led to the need for the Port Authority of New York and New Jersey (PANYNJ) to upgrade JFK International Airport to accommodate this enormous plane. Alterations included the relocation of Taxiway A North and South, and the rehabilitation of Taxiway B North.

Conti performed the taxiway relocation and rehabilitation to properly land the Airbus 380, all while working at a very active, high security international airport. Under this contact, Taxiway A (75 feet wide) was shifted 16 feet for a total length of over four miles.

The team placed over 90,000 cubic yards of cement-treated base and 208,000 tons of other paving materials while minimizing disruptions to airport operations. Conti batched all cement base on site from recycled millings and Lime Cement Fly Ash (LCF) base material from previous excavations into a sustainable environmentally friendly material called “econocrete”. This approach eliminated the need for 25,000 cubic yards of virgin material and 2,200 truck trips. In addition to saving PANYNJ money, Conti shaved time on the project by producing 1500 yards of the cement-treated base on site per day.

Conti also met stringent FAA runway smoothness standards for the precise quality control specifications of a maximum profile index of 15 inches/mile with no individual deviations greater than 0.4-inches in 25 LF.

Conti’s newly patented “econocrete” technology garnered huge saving for the client and surpassed sustainable goals.

Newark Airport Terminal B Bridges and Pump Stations

As America’s oldest airfield and home to the first commercial airline terminal, Newark Liberty International Airport (EWR) made aviation history when it opened in 1928.

Today it serves as a critical transportation artery for the New York City metropolitan area. As part of continual upgrades and maintenance, the Port Authority of New York and New Jersey (PANYNJ) called for upgrades to EWR’s lower level passenger arrival hall to accommodate over 35 million people each year. The agency also wanted to eliminate parking lot flooding issues.

Conti installed new underground pump stations for flood control, constructed a new bridge structure, and widened a second bridge to provide access to the new lower level of Passenger Terminal B. The team constructed three storm water pumps for evacuation of storm water, collectively capable of expelling over 45,000 gallons of water per minute from EWR’s parking lots. Conti performed shoring, dewatering, permit procurement, excavations, and sheet piling during these operations. As a part of the two-phase bridge construction, Conti poured approximately 175 cubic yards of 4,000-psi category IV Port Authority concrete for each phase, all along two bridge decks that each measured over 190 feet long.

The team handled over 300 client-driven modifications resulting from unforeseen conditions and still completed work on schedule and on budget, while keeping parking spaces and pedestrian walkways open throughout the project.

Conti’s work alleviated the frequent flood issues that plagued one of the nation’s most important airports, and also allowed for easier access for travelers.

Newark Airport Terminal A Bridges

As America’s oldest airfield and home to the first commercial airline terminal, Newark Liberty International Airport (EWR) Terminal One Redevelopment project will set a new standard for air travel.

Today it serves as a critical transportation artery for the New York City metropolitan area. As part of continual upgrades, the Port Authority of New York and New Jersey (PANYNJ) called for this program which will be the largest design build project in New Jersey’s history.

Conti has broken ground on this contract which consists generally of furnishing and installing underground electrical and communications duct banks, water and sewer lines, overhead signs, roadways and intelligent transportation system, canopy structures and landscaping, and construction of Bridges N61, N62 and N63, and related work at Earhart Drive and Parking Lot P3 and the vicinities thereof at Newark Liberty International Airport, New Jersey.

The team will safely manage construction activities while avoiding any potential impact to current operations.  
This contract is part of the Terminal One Redevelopment Program which is set to replace Terminal A, the airport’s oldest Terminal.