CASHMAN ink APRIL 2013
HUDSON
DREDGING REVIEW
OVERCOMING OBSTACLES AT
DANIA CANAL ARTHUR KILL
& NEWARK BAY DEEPENING
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A Cashman Companies Publication
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IN THIS ISSUE:
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CASHMAN REWARDS INNOVATION
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OBSTACLES AT DANIA CANAL
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INDUSTRIAL POWER CONTRACTORS
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UPLAND FILL
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PRELOAD HEADS WEST
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FORT PIERCE MARINA
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2012 HUDSON DREDGING REVIEW
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PRELOAD CAME A-KNOCKING
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STERLING EQUIPMENT
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ENERGY UPDATE
ARTHUR KILL & NEWARK BAY
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EMPLOYEE NEWS
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CASHMAN INK APR 2013
Jay Cashman, Inc. is a comprehensive construction company, well regarded within the industry for its diverse technical capabilities, professional project management and consistent performance. From senior managers to site superintendents, from accountants to equipment operators, Cashman employees are experts in their fields. This expertise combined with high standards, determination and confidence enables Jay Cashman, Inc. to take on some of the most difficult dredging, marine, heavy civil, and environmental projects in the world.
EDITORS: EDITIORS: Megan Sylvia Jaclyn Cashman Childs
CONTRIBUTING EDITORS: Will Spielvogel Norm Bourque Lindsay Galbraith John Riffey Mark Quinn Dan Pecario Marc DePalma Steven Dudle, P.E. Robert Barbarisi, Jr. Frank Campea Elyzzah Heffernan Dario DiBona
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CASHMAN
REWARDS
INNOVATION By Megan Sylvia As the Cashman Companies continue to grow and take on increasingly complex projects in more areas of the world than ever before, they recognize the power and significance of innovation. Jay Cashman, Chairman, encourages all employees to be involved in idea creation, and has recently implemented a program to reward employees for their original thinking. To get involved in the innovation program, Mr. Cashman asked all employees to write down any original idea by the end of the year and submit them to him for review. Ideas that he feels have potential to succeed will be implemented.
Mr. Cashman held a meeting for employees in early October to announce the program to promote innovative thinking. The meeting was followed by a workshop on October 18th to discuss employees’ ideas, the ways ideas are generated, and more detail on the program. At the meeting, Cashman communicated his vision for innovation within the company. “I want to see that the Cashman group has created tools, developed ideas, and invented new strategies that are different,” Cashman said. “I’m looking for innovation across the board. Every person in this room has an opportunity to participate in this.”
“THE GOAL IS TO MAKE EVERYONE AN INVENTOR HERE”
At the end of 2013, the person with the concept that Mr. Cashman feels was most innovative will be rewarded with $25,000. The next three best ideas will each earn $5,000. Cashman believes that ongoing innovations, whether large or small, are imperative for a company’s growth and success.
Cashman employees getting 4 ready for innovation meeting
From developing the next cutting-edge type of dredge to replacing an outdated accounting procedure, the Cashman Companies welcome innovation in all areas and departments. They realize that even the smallest changes behind-the-scenes can play vital roles in increasing the overall efficiency of the companies, and with this program, Mr. Cashman hopes that employees will be encouraged to bring such improvements to light.
During the workshop, employees volunteered to share their ideas, while others offered suggestions of how the concepts could be further evolved.
Later, Cashman shifted gears and asked employees to share times in the past when they had dreamt up a big idea, and how that idea came into inception. “The goal is to make everyone an inventor here, and to give the resources to make something happen,” said Cashman. “I believe there’s a good idea in everybody.”
Jay Cashman, CASHMAN Chairman
INK APR 2013
UPLAND FILL By Will Spielvogel Jay Cashman, Inc. is currently on site at the Upland and Wall Fill Project in South Carolina. The project was awarded by the South Carolina State Ports Authority in April 2012. This is the second phase for construction of a new container terminal for the Port of Charleston on the Cooper River on a former Navy base. Cashman completed the first phase for this project a year ago, constructing 5,000 linear feet (LF) of containment wall, dredging some 700,000 cubic yards (CY) During this project, approximately 2.0 million CY of sand material is being mined from the existing dredge disposal cells at Daniel Island approximately 2 miles from the jobsite across the Cooper River. The material is loaded onto a 500 ft. long conveyor system and onto barges. The barges transit across the Cooper River where approximately 600,000 CY will be placed via a 150 ft. floating conveyor behind the containment wall. The remaining material will be trucked from the front wall uploading area to upland and will be used to construct a surcharge embankment for the future terminal facility site. Other work being done during the project includes the clearing of approximately 250 acres, installation of about 6 million LF of wick drains, geotechnical instrumentation, sheet pile installation, 1,000 LF of 54“ HDPE outfall pipe and the placement of 200,000 tons of riprap and armor stone. Stone materials are delivered by a 50,000 MT cargo ship from New Brunswick, Canada. A custom conveyor system arrived on site near the start of the project, which was assembled on barges to load sand materials from Daniel Island and to offload materials at the project. Completed work to date includes the placement of approximately 125,000 tons of riprap and armor stone, 352,000 CY of sand behind the containment wall, 328,000 CY of sand as surcharge embankment, installation of all the geotechnical instrumentation, and almost all 6 million LF of wick drains. Currently, armor stone is being placed along the front wall and sand is being placed uplands as site fill surcharge material. The first phase for sand material placement and stone placement around the containment wall is to be completed in May 2013 with the balance of work scheduled to be complete by December 2013.
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Unloading and grading sand uplands as site fill material for the surcharge embankment.
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2012
HUDSON
DREDGING REVIEW
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As December came to a close, so did Cashman Dredging and Marine Contracting Co.’s third year of dredging and backfill/capping operations for General Electric on the Hudson River in New York. Cashman doubled its production from previous years, improving efficiencies for GE in the process.
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By Norm Bourque It is said that, “the third try is the charm,” and this was very true for the third Hudson River dredging season. General Electric (GE) spent the winter of 2011/2012 constructing a second off-loading and size separation station at its Sediment Processing, Treatment and Transportation Facility. Cashman provided most of the heavy civil construction under the direction of Chris Sheedy, Project Manager, Shawn Rebello, Superintendent, and Greg Beaudet, Superintendent.
Surpassing Goals “This added off-loading capability provided Cashman an opportunity to show that not only could we meet project production goals, but we could shatter them,” said Norm Bourque, Project Director. EPA’s goal for 2012 was to dredge 350,000 cubic yards (CY) and remediate 28 certification units (CU’s). By August, it was apparent that Cashman was on pace to dredge in excess of
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500,000 CY, so GE issued Cashman a change order to dredge an additional five CU’s that were planned for the 2013 contract as well as an additional five CU’s in an area known as West Griffin Island. When the final amounts were tallied at the end of the season, Cashman had dredged 663,265 CY, which is more than was dredged in 2009 and 2011 combined. Not only was dredging production doubled from previous years, but the fast pace of dredging required the backfill and capping production to be ramped up as well. Cashman was able to provide GE these production increases while improving efficiencies for the Owner. In December of 2011, Cashmansuccessfully negotiated a new PLA for the 2012 season that reduced the crew size on the dredges from four men to three, which also reduced management staffing requirements on the project.
CASHMAN INK APR 2013
Over the last three seasons, Cashman has dredged 52 of the 100 CU’s, or approximately 260 acres of river bottom starting in the Village of Fort Edward and continuing five miles downstream. For the 2013 dredging season, GE has targeted another 19 CU’s, or 95 acres. These CU’s are spread out over seven miles of river. As dredging progresses downriver, the dredge areas become more discrete and dispersed, which poses greater logistical challenges.
Background After more than 10 years of studying the river, on December 6, 2000, the EPA announced a five-year plan to dredge 2.65 million cubic yards of PCB-containing sediment along a 40mile stretch of the river below two GE factories in Hudson Falls and Fort Edward. After review and public comment, the plan was embodied in a Record of Decision issued by EPA in 2002. GE agreed to implement EPA’s project and began to collect thousands of samples of river bottom sediments to assess
the specific location and depth of PCBs in sediments. GE also began to design the project to meet EPA’s strict engineering and quality-of-life performance standards. In 2007, GE began to build a sediment transfer and processing, treatment and transportation facility. In 2009, the first phase, or first year, of dredging commenced. After a year of evaluation and review, the second and final phase of the project began in 2011. This phase encompasses 40 miles of river from Fort Edward to Troy, N.Y.
Meeting Challenges with Innovation The 2012 dredging season brought a number of new opportunities for the Cashman Dredging management team and the craft personnel to show the owner Cashman’s capabilities. Although the challenges associated with the ramped-up production were first and foremost last year, the project provided three other major challenges.
GE Project Team. Left to right: Chris Sheedy, Danielle Taylor, Norm Bourque, Tim Mannering, Charles Towle
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The first new challenge was the segregation of dredged materials into two categories: TSCA and Non-TSCA material. The acronym TSCA stands for Toxic Substance Control Act. Sediment that has in-situ concentrations of 50 PPM (Parts per Million) of PCBs or greater is considered to be TSCA material and has to be disposed of in accordance with TSCA guidance. Sediment with in-situ concentrations less than 50 PPM is managed under less stringent disposal requirements. Although everyone on the project played an active role in meeting this new challenge, two people stand-out as key personnel who made it all work: Corey Welch, Operations Manager, and Rob Vuksanic, Assistant Project Engineer. The second new challenge last year was dredging and backfill/capping operations in a small, shallow channel behind three islands, appropriately named Three Sisters Islands. This area comprised two CU’s and was incredibly confined. The work here started in June and was completed in December. The two people who deserve the lion share of the credit for organizing this work are Tim Mannering, Project Engineer, and Shawn Rebello, Superintendent.
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The third new challenge was the addition of five CU’s in a channel behind West Griffin Island. Cashman was able to come up with innovative dredging solutions for the owner in order to maintain dredging production while at the same time minimizing the volume of access dredging required in this area. Each year that Cashman Dredging has worked on this project has differed from the prior years; 2012 was no exception. Cashman has already begun planning for the 2013 season, which brings with it new challenges, including logistical issues, safety issues associated with dredging and backfill/capping within two-hundred feet of a dam, as well as potentially moving our support yards to new locations down river. Additionally, Cashman is providing expertise and oversight to the owner to build long haul tugs and larger hopper barges in order to maximize the volume that can be transported over long distances. Cashman is also developing solutions to dredge shorelines more effectively while at the same time reducing the amount of water loaded into the hoppers.
CASHMAN INK APR 2013
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ENERGY UPDATE: PATRIOT RENEWABLES
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A view of the Spruce Mountain Wind Project in Maine. CASHMAN Woodstock, INK APR 2013
By Lindsay Galbraith
Spruce Mountain’s Status Patriot Renewables’ 10-turbine Spruce Mountain Wind Project in Woodstock, Maine began commercial operations on December 21, 2011. Spruce is now running smoothly, providing enough electricity to power approximately 10,000 homes each year. Patriot is receiving a lot of positive feedback from people that live in the area.
The partnership closed on the property in February 2012. Patriot is investigating the site’s potential for a wind project, in addition to other possible uses. This site has the potential to support as many as 30-40 large-scale wind turbines, which would be the largest project in their portfolio.
Giving Back
CONGRATULATIONS!
As a new member of the Woodstock community, Patriot has sponsored a $5,000 college scholarship contest, purchased a floating dock for a nearby pond, and donated to several local organizations. For Spruce project updates and photos , “like” their Facebook page at www.facebook.com/ sprucemountainwindproject
Through the hard work of Andrew Goldberg, Cashman Companies Chief Financial Officer, Patriot Renewables, LLC was awarded a $13.1 million cash grant under the American Recovery and Reinvestment Act of 2009 for the Spruce Mountain Wind Project.
Reducing Energy Costs Patriot has also made improvements a little closer to home. Construction of a 164.5 kW solar project began in late November on the rooftop of the New England Aquarium’s Animal Care Center in the Quincy Shipyard. The project consists of seven hundred 235W Jinko Solar panels, which are expected to generate approximately 183,000 kWh each year. This project will produce enough power to offset over 10% of the building’s total energy usage.
In the Works Patriot has several other sites in various stages of development. The permit for the 12-turbine Saddleback Ridge Wind project in Carthage, Maine is currently under appeal. Site work on the new substation that will be built for the project has already begun, and Patriot hopes to start construction on the ridgeline portion of the project in early 2013. A permit application for the 8-turbine Canton Mountain Wind project in Canton, Maine is being reviewed by the Maine Department of Environmental Protection and Patriot expects to receive the permits by the end of the year. Patriot has begun a new project in Moscow, Maine. Jay Cashman, in partnership with Conroy Development and Cianbro Corporation, acquired a 1,400-acre site from the Federal GSA that had been previously used as a radar base to search the northern hemisphere for inbound nuclear missiles during the end of the Cold War.
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From left to right: Andrew Goldberg, Jay Cashman, and Todd Presson
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By John Riffey
OVERCOMING OBSTACLES .AT. DANIA
CUT OFF CANAL 14
For the past nine months, the dredge “Jay Cashman” has been chartered to Lucas Marine Acquisition Company (LMAC) and working in South Florida at the Dania Cutoff Canal. The Florida Inland Navigation District contract to deepen the canal was awarded to LMAC with the Notice to Proceed issued on March 23, 2012. Bruce Wood, working as a consultant to LMAC, was appointed Project Manager, and work began immediately with construction of the Dredged Material Management Area (DMMA).
Beginning Construction The site was cleared, berms constructed, and a “lazy river” settling facility was built to allow for the return of clean water to the canal. Several unique ideas for accomplishing the offloading of barges were brainstormed, but it was decided to drive piles and construct a landing area where the barges
CASHMAN INK APR 2013
Dredging operations at the Dania Cut Off Canal
could be moored and unloaded by a Sennebogen 870. This was one of the first obstacles to overcome, as the width of the channel and the needs of boat and ship traffic had to be taken into consideration. LMAC also had to devote a great deal of time and energy to ensure compliance with stringent environmental requirements. Shields had to be fabricated above mangrove areas and turbidity curtains were placed to protect seagrass beds. In the end, all was well and the DMMA Facility was open for business on schedule.
Amendment Work The optional bid item was exercised to remove approximately 3,000 cubic yards of material in front of the Port of Everglades Berths 31/32, and dredging began on June 23, 2012. The material consisted of a sand/broken shell mix, and the controlling depth was 42.5’ with 1.5’ of allowable overdepth. The berth area dimensions were 1,000’ in length by 100’ wide.
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High tide presented LMAC with the challenge of how to continue dredging with floating spuds. They scheduled work close to the pier during high tide and literally moored the dredge to the pier as they dug. LMAC was fortunate to have very skilled and experienced dredge and tender tug operators, Robert Fowler and James Andress, as they made a very difficult job look easy. Another unique challenge was that no special allowance was made for traffic or berthing schedules, yet the “Jay Cashman” and crew managed to accomplish the task ahead of schedule, in spite of working in front of the busiest container berths in Port Everglades. Dredging at berths 31/32 was completed on July 8, 2012. After a bucket change, the “Jay Cashman” immediately started the deepening portion of the Dania Cutoff Canal Project.
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Design depth is 15’ with 2’ of allowable overdepth. The working area is 4,770’ in length, broken into 1,000’ reaches (except for Section 5 which is 770’ in length), and varies in width from 160’ down to 75’. All structures, mangroves, and eelgrass had to be surveyed and 25’ offsets were built into the template for all structures and 10’ offsets for all mangroves and eelgrass areas. Dredged material has consisted of everything from mud to hard rock. Plenty of tires of all sizes were brought up, as well as old cables, anchors, pipes, and several thousand beer cans of various age, identified by having been opened by a “church key”, a pull tab, or the current pop top.
water quality permit, as turbidity increased greatly. One Best Management Practice method to decrease the turbidity levels was to slow down the dredging cycle. This goes against the natural instincts of every good operator, yet LMAC managed the operation effectively in its effort to minimize turbidity as much as practicably possible to remain within compliance. In addition to the usual set of challenges LMAC encountered and overcame on the water, they have been tested on land, as well. The DMMA requires constant management to maintain a proper area for the dredged materials as Bruce Wood seeks a “home” for it. A good portion of the spoils are going to the
Additional Challenges One of the more serious obstacles LMAC has been facing is the high volume of civilian and commercial boat traffic. Also, as the winter season began, there was an influx of megayacht traffic, which effectively cut the width of an already narrow channel in half. Upon reaching Section 4, it was discovered that there was a layer of hard rock capping over limestone, which was underneath 3’-4’ of soft material. After removing the soft material, the environmental bucket was replaced with a conventional hard rock digging excavator bucket. Although production was slower than in the specified soft material, the “Jay Cashman” was ultimately able to dig the rock. The issue soon became how to remain in compliance with the
construction site for the new work that is being done to expand the Fort Lauderdale International Airport. On December 7, 2012, a total of 137 truckloads of dredge material were taken off site in approximately 8 hours. With the constant equipment and truck traffic on the site, the DMMA has performed very successfully while putting safely first. In spite of many unique and challenging situations, morale and pride of workmanship remain high, and LMAC is projected to finish ahead of the scheduled completion date. The client, Florida Inland Navigation District, is very pleased with the progress and quality of work to date. In spite of many unique situations, morale and production remain high and LMC is projected to finish ahead of schedule. The client, Florida Inland Navigation District, is very pleased with the progress and quality of work to date.
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CASHMAN INK APR 2013
PRELOAD CONSTRUCTION HEADS WEST By Dan Pecario & Marc DePalma After approximately 35 years, Preload has re-emerged out West and is set to build its first tank in a western territory since 1977. Construction began in late July on a 3.0 MG tank in Montrose, Colorado. The final tank design led to a tank capacity of 3.0 MG, with an inside diameter of 152 ft and a liquid wall height of 22 ft. The tank is expected to be substantially complete by April, 2013.
Teaming Up for Success
Cutting Costs The design-build procurement method allowed Preload a unique opportunity to present value engineering alternatives in order to provide the most cost efficient, high quality project possible. Major cost savings were achieved by eliminating the drilled pier foundation required in the proposal, which subsequently reduced the 24” thick structural floor to a 6” thick membrane floor. By installing standard ductile iron fittings rather than an expensive tank mixing system, Preload cut costs even further. Overall, we were able to provide substantial savings to the City of Montrose due to value engineering alternatives.
Besides being the first Preload tank built in Colorado in 49 years, this design-build project “The Montrose, Colorado project has truly had a unique delivery system been a collaborative effort, combining work which required an extremely from the Sales, Estimating, Engineering, and collaborative effort from the Construction Departments at Preload. We project team.
Procuring Permits
One of the unique aspects of this construction project has been the extensive permitting process required, due to the existence of an are excited to build our first tank in a western endangered plant on-site called territory in 35 years and we know that our The experience level and the ‘clay-loving wild buckwheat’. success out west will continue for years to influence of the design-build In order to meet stringent consercome!” -- Preload team, consisting of a consulting vation requirements, Preload had engineering firm, The Engineering to procure permits from the Army Corps of Engineers and the Company of Fort Collins, Colorado, a local site work contractor, Colorado Department of Public Health and Environment, as Skip Huston Construction of Montrose, Colorado, and Preload, well as gain approval from the U.S. Fish & Wildlife Service. was a key factor in winning this job. Spear-headed by Preload and competing against Natgun and VSL, an AWWA D115 Tendon tank company from Colorado, the Preload team successfully procured the contract.
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Although the permitting requirements delayed the start of construction, the project is expected to be completed by the deadline.
Montrose, 17 Colorado site.
Central Storage site dome placement
PRELOAD CAME A-KNOCKING... By Steven Dudle, P.E., Robert Barbarisi, Jr., & Daniel Peciaro …And Butler answered the door. Butler, Pennsylvania, that is. In June 2012, Preload completed construction of five dome-roofed Flow Equalization (EQ) Tanks for Butler Area Sewer Authority (BASA). This is one of the largest and most successful projects completed by Preload in recent memory. It was finished on time and under budget.
Background In 2009, the owner, BASA, was under a consent order to build Combined Sewer Overflow (CSO) Storage to comply with Pennsylvania Act 537. During wet weather events, the BASA treatment plant was forced to release sewage treated below secondary standards into the local watercourse. For this reason, BASA entered a design/bid/build contract with Chester Engineers to site and design a total of seven EQ tanks to be built in three separate sites in the service area. In October 2010, Preload was the low bidder on Contract 23 which was the combined contract for three 4.7 MG EQ tanks at the Central Storage site and two 1.0 MG EQ tanks at the Monroe Storage site.
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The Pre-Construction meeting was held on February 3, 2011, and on March 31, 2011, Preload broke ground on the Central Storage site. This was followed by the April 13th groundbreaking at the Monroe Storage site. The Central Storage site was formerly a slag waste area for a train axle factory and was classified as a ‘brown field’ industrial reclamation site. The Monroe Storage Site is a downtown site bordered by two busy streets and a local stream, the Connoquenessing Creek. The three 4.7 MG tanks at Central Storage are each 154’ Inside Diameter (ID) x 35’ Side Water Depth (SWD); the two 1.0 MG tanks at Monroe Pump Station are each 87’ ID x 23’ SWD.
An Environmental Advantage A particularly unique aspect of the construction at Central Storage was the implementation of a soil improvement system installed by DGI-Menard, which consisted of nearly 500 Controlled Modulus Columns (CMCs) installed at the foundation of each tank. Unlike driven-pile foundations, the CMC system is installed by utilizing a drill rig attached to a mobile grout pump.
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Defining features of the CMC technology include:
• The material is grouted in place through the use of a displacement auger
• Improved soil properties between columns in granular
soils through use of displacement drilling of lean sanded grout
• Virtually no spoils are generated by the drilling process,
which eliminates the substantial cost and risk associated with the disposal of contaminated soils
• Well suited for very soft soil conditions such as organic clays, peat or municipal solid waste
Using a specially designed displacement auger, the CMCs are installed in such a fashion to allow for lateral displacement of the soil without generating spoils or creating vibrations. The displacement auger is hollow, and this allows for placement of the specially designed grout column. Once drilling reaches the desired depth, the auger is withdrawn and grout or mortar is pumped through the hollow stem of the auger and into the soil cavity. Operations are continuously monitored by means of an advanced computer system installed in the cab of the drill rig. This enables the operator to control the withdrawal rate of the auger so that grout back-pressure is never lost, thus
HARRIS COUNTY, TEXAS By Daniel Peciaro
ensuring a consistent column width and eliminating the possibility of ‘necking.’
Added Features At the Central Storage site, CMC operations commenced with the installation of a working mat at the location of each tank. CMC Layout was based upon design calculations, and typical spacing ranged from 6.75 – 7 feet to an average depth of 15 – 30 feet from the working pad elevation. 3500 psi grout was used for each CMC. Additionally, because the EQ tanks are designed as wet weather event tanks for periodic use only, they are equipped with remotely operated high pressure wash down equipment. The washdown system installed at each of the five tanks consists of ductile iron pipe attached vertically along the exterior wall surface, and extends horizontally across the tank dome to the center. The washdown piping is connected to an interior cleaning machine through a penetration in each tank dome. Designed to create a mixing pattern matrix similar to a ball of twine, the cleaning machine body rotates axially to allow for optimum coverage. At approximately 10% of the cost of more ‘conventional’ tank cleaning methods, this highly innovative technology effectively eliminates the need for confined space entry, in addition to the need for internal structures such as platforms and walkways or operated water cannons.
as improve the sustainability of the project by self-generating power and returning excess energy back into the grid. This project was completed in May 2012.
Exxon Mobile recently developed a 1,800 plus acre tract of land North of Houston, Texas in Harris County Improvement District #18. In this upscale development, aesthetics were very important. The aesthetics for the new water storage facility were addressed by Morris Design Studio, an architectural firm in Castle Pines North, Colorado, including architectural treatments for the new 1.15 MG prestressed concrete potable water tank. Engineering for the plant was handled by Costello, Inc. of Houston, and Preload designed and constructed the tank as well as the unique solar panel support structure. Solar panels will add architectural value to the tank project, as well
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3D rendering of the Harris County, TX development
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CASHMAN INK APR 2013
NEWARK BAY & ARTHUR KILL
50-FOOT DEEPENING By Stephen Tobin Cashman Dredging and Marine Contracting Co., LLC (Cashman), in a Joint Venture Partnership with Donjon Marine know as Northeast Dredging Equipment Company, LLC (Northeast Dredging), has successfully completed two capital dredging projects for the United States Army Corps of Engineers (USACE) – New York District as part of the on-going 50-foot Harbor Deepening Program in the Ports of New York and New Jersey. The Newark Bay and Arthur Kill Channels Navigation Improvement Project (S-NB-2/S-AK-1) Contract 11 and the Arthur Kill Channel Navigation Improvement Project (S-AK-2) Contract 13 were among the largest drilling and blasting dredging projects on the east coast of the U.S., and were under the oversight of the USACE, New York District. The S-NB-2/S-AK-1 and S-AK-2 Projects involved dredging in hard rock in one of the busiest shipping channels by cargo volume and vessel traffic on the east coast. Hard rock drilling and blasting operations included construction of an artificial mitigation reef, controlling marine traffic, coordination with local, state, and federal authorities, off-shore disposal, and bathymetric survey. The projects were heavily resourced. At its’ peak, Cashman coordinated and managed activities of 13 on-water vessels, employing more than 50 craft personnel and 17 management personnel to oversee operations. In addition, the work had to be coordinated with multiple entities such as the US Coast Guard (USCG), adjacent contractors, public agencies, abutters and the general public.
Newark Bay Northeast Dredging began work on the Newark Bay project (S-NB2/S-AK-1) in December 2010. The project began with the removal of approximately 531,000 cubic yards (CY) of fine silts for disposal in the Newark Bay Confined Disposal Facility (NBCDF) or for beneficial reuse at upland facilities. Approximately 163,000 CY of material were removed and placed in the NBCDF. The remaining 368,000 cubic yards of material were processed with Portland cement and transported to various approved permitted upland facilities for beneficial reuse as cap material.
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Following removal of the silt materials, Cashman drilled and blasted approximately 2.1 million square feet of rock. The Joint Venture dredged approximately 2.4 million CY of clay, sand and blasted rock. The project was completed on October 26, 2012, approximately two months ahead of the Contract completion date.
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Arthur Kill
Underwater Drilling & Blasting
Northeast Dredging began work on the Arthur Kill project (S-AK-2) in December 2011, while S-NB-2/S-AK-1 was still on-going. The two projects were executed simultaneously, managing resources on both projects in order to keep on schedule.
For both projects, Cashman was in charge of operating the drill boat Kraken in order to perform underwater drilling and blasting, and under its existing ATF license, was responsible for
The project began with the removal of approximately 391,000 cubic yards (CY) of fine silts for beneficial reuse at upland facilities. Following removal of the silt materials, Cashman drilled and blasted approximately 3.3 million square feet of rock. The Joint Venture dredged approximately 1.4 million CY of clay, sand and blasted rock. The project was completed on March 5, 2013, approximately two months ahead of the Contract completion date. In addition, the USACE project oversight personnel informed the Joint Venture that the S-AK-2 project was the first harbor deepening project to have all Contract Acceptance Areas accepted as complete on the first USACE hydrographic acceptance survey. Rock initially removed from the S-NB-2/S-AK-1 project was transported to the Axel Carlson reef located off the coast of New Jersey to complete the creation of an artificial reef. All remaining rock from the two projects as well as the clay and sand materials were transported offshore to the Historic Area Remediation Site (HARS) for placement. A total of 2,109 trips were made to off shore disposal locations from both projects.
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all drilling and blasting operations in preparation for dredging to the required grade. Drilling, blasting and dredging operations had to be strategically planned and implemented without interruption to one of the nation’s busiest harbors in order to maintain safety and efficiency during project operations. The USACE, USCG, NY Department of Environmental Conservation, NJ
CASHMAN INK APR 2013
Department of Environmental Protection, the Port Authority of New York and New Jersey, Metro Pilot, Docking Pilots, Sandy Hook Pilots and other local entities were all heavily invested in the progression of the work and required a concerted coordinated effort. Channel navigation for Commercial and Public vessel traffic had to be maintained at all times. In order to effectively control ongoing operations, Cashman equipped all project vessels with AIS transponders and checked in with the Coast Guard Vessel Traffic Service every two hours to update equipment locations and to coordinate movements.
Navigational & Articulated Buoys Project management worked closely with the U.S. Coast Guard and Harbor Pilot Organizations to facilitate multiple federal navigational buoy movements in order to establish a working channel free of navigational hazards during drilling and blasting operations. In addition to the federal navigational buoys, articulated buoys were required to designate the working channel in two Acceptance Areas in S-AK-2. The red and green articulated navigational buoys were provided by the USACE and installed and maintained by Cashman while drilling and blasting operations were on going in these two areas. Cashman worked closely with both the docking pilots as well as the USCG for each move of the articulated buoys.
The articulated buoys are not owned or operated by the USCG but are still considered official navigational aids and required approval prior to each movement. The use of the articulated buoys in both of the areas effectively reduced the working navigational channel for vessel traffic by half. The narrowed channel created a challenge for vessel traffic and dredging operation safety and was closely monitored at all times.
Work Completed As stated by one of the Harbor Pilots following completion of our work: “From all the Harbor Pilots of NY/NJ, thank you for making a difficult and risky situation manageable and workable for us. By your efforts and ready communications, what can often be an adversarial relationship became a true partnership delivering results often ahead of schedule. The next contractor will be held to the high standards you and your team established�. The projects would not have been a success without the tireless efforts of Cashman employees. Cashman would like to thank: Chris Bonn, Paul Poirier, Richard Barber, Dean Chambers, Micah Bowers, Steve Baynes, Nathan Gilbert, David Norton, Gerry Donlevy, Danielle Taylor, Corey Welch, Tim Mannering, Kyle Reeves, Dean Kirby, Geoff Crews, Alex Serrano, Dominick Dunston, Neal Twaddel, Jake Minevitz, John Chang, Pete Gibson, Dave Wasniewski, John Durante, and all those who assisted us at Sterling Equipment for your exceptional contributions over the past 2 years.
The Kraken drillboat at work on Newark Bay in Elizabeth, NJ
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INDUSTRIAL POWER CONTRACTORS By Frank Campea
Industrial Power Contractors (IPC) is a full service power generation and industrial contractor serving the Northeast markets and beyond. Throughout the past year the company performed projects for over twenty customers in the region including plant owners, EPC contractors and OEM’s noting the following companies:
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Millennium Power Dominion Energy Berkshire Power Tiverton Energy MIT Cambridge CHP MIT / Lincoln Labs Mass Port Fischbach & Moore Bay Crane
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Foot Print Power Mass Crane Braintree Power Rolls Royce Turner Envirologic L’Energia Green Wind, LLC Capital Power Siemens
2012 Granite Ridge Continuing Service Contract Londonderry, NH An important part of IPC’s business is providing scheduled and emergency power generation maintenance services. In the case of the Granite Ridge Continuing Service Agreement, IPC has a full set of tools and equipment on-site and ready for any outage or service needs that may arise.
The company offers an array of services including boiler and back end construction and repair, power & process pipe fabrication and installation, machinery erection and overhaul, heavy rigging, structural steel design, fabrication and erection, and general contracting services. Construction and maintenance services can be provided bundled or unbundled depending on customer needs.
Phillips Lightolier Wind Turbine Project, Fall River, MA In the spring of 2012, IPC was contracted to erect the Philips Lightolier 2 MW wind turbine. Their work on the Chinesemade SANY turbine included installation of the embedded turbine foundation and erection of the 85 meter tower, nacelle, and rotor. The company provided engineered lift plans and an erection procedure for all work performed utilizing a Liebherr LR 1400, SDBW – 500t crawler crane and a Liebherr LTM 1090-4.1 110t hydraulic assist crane.
Granite Ridge Energy Gas Heat Exchanger Repairs
Philips Lightolier 2 MW Wind Turbine
Over the year, the company performed numerous ASME Section 1 Boiler and Pressure Vessel repairs, Gas Turbine Exhausts flange crack repairs and piping system modifications and repairs as needed. Granite Ridge has a scheduled spring 2013 outage that IPC will be performing a significant amount of work.
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REPORT Exelon Corporation Mystic Station Facility Access Modifications, Everett, MA A particular niche service offered by IPC is their in-house ability to design, fabricate and erect facility and equipment access solutions in existing plants. Often times, power generation facilities are built with limited access to critical components resulting in “permanent” scaffold installations that are costly and require constant maintenance and inspection. IPC offers turnkey solutions for these situations. They provide the customer with onestop-shopping by incorporating all design, fabrication, plant and system modifications, and erection services.
USNS KEOUK Main Reduction Gear Overhaul – Philadelphia Gear Corp. Portsmouth, New Hampshire Philadelphia Gear Corporation (PGC) is one of the largest gear manufacturers and service providers in the United States. And, with the recent acquisition of General Electric’s US Navy Marine gear business, Philadelphia Gear now owns the intellectual property of 90% of marine gearing in the US Navy Fleet. Industrial Power Contractors has been selected by PGC to support their efforts of repairing this equipment as well as other industrial drive applications throughout industry.
One project performed this past year was at Exelon’s Mystic Station Units 8 & 9 in Everett, MA. Working with a tight schedule, IPC efficiently designed, fabricated and erected numerous boiler and valve access systems in time for a scheduled plant shut down.
Exelon – Mystic 8 & 9 Access Modifications
USNS KEOUK Main Propulsion Reduction Gear Overhaul
Over the past summer, IPC was challenged with overhauling the USNS KEOUK’s main propulsion gear at Portsmouth Naval Shipyard. The YTB 771 tug’s mission includes maneuvering submarines in and out of their births at the shipyard. The overhaul was required due to damaged bearings and a distorted casing from decades of propulsion cycling. IPC’s scope included interference removal and restoration, gear disassembly and refurbishment, on-site line bore machining of gear bearing bores, reassembly, shaft alignment and testing. This on-board and in-water project was challenging, however IPC performed all work to the Navy and PGC’s full expectations.
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NEW BARRIER ISLANDS
PROTECT CITY MARINA Several years after the 2004 hurricane season left the Fort Pierce City Marina decimated, Lucas Marine Construction began building new barrier islands to protect the marina and provide a new home for marine life.
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By Megan Sylvia & Elyzzah Heffernan
Background The waterfront city of Fort Pierce, Florida experienced extreme damage to their marina as a result of the 2004 hurricanes. Many of their docks and basin slips were destroyed. FEMA agreed to fund the replacement of the docks if a solution was engineered to protect them from future storm damage. As a result, the city set out to design and permit barrier islands to protect the marina, a process that took nearly 7 years. Stuart, Florida based Lucas Marine Construction, LLC, a Jay Cashman, Inc. affiliate company, was awarded the Fort Pierce City Marina Reconstruction Phase I: Island Storm Protection project to build a total of 13 islands, including one large island and 12 smaller ones. The project kicked off on May 10th with the city’s “Big Splash” groundbreaking ceremony, and is well through construction. The barrier islands are expected to be completed by May 2013. After they are built, the next phase of the project will be issued for bid to replace the docks with 287 new slips.
Working with Challenges Much of the limestone is being placed in as deep as 25 feet of water. Placing rock in such conditions requires good planning, careful placement, and divers onsite to assist. Lucas Marine
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Construction also invested in Trimble survey equipment, which has been a key to accurate placement. This project additionally requires many activities to take place simultaneously, so coordination of activities is crucial to the success of the project. At any given time, there are six independent tasks taking place concurrently, each with its own crew and equipment.
Creating a New Habitat The engineers designed the islands to double as a new habitat. Marine mattresses containing natural limestone rock are being used to build the islands, which when placed, create an almost immediate new home for fish and vegetation. Workers on site continue to marvel at how quickly new sea life appears. The islands will also act as an oyster reef. A total of 90,000 tons of limestone and approximately 120,000 cubic yards of sand fill will be installed. The storm protection system will enhance the estuarine habitat of the Indian River Lagoon with 1.28 acres of oyster mats and 2.33 acres of potential shore bird habitat. In addition, a separate contracted company is responsible for creating 6.26 acres of artificial reef, 2.22 acres of coastal dune, 8.12 acres of sea grass beds, and 1.54 acres of Mangroves. Although the islands won’t be open to the public, snorkeling and diving off the south area of the islands will be allowed.
CASHMAN Geotextile INK APR 2013 Tube Filling
CONSTRUCTION PROGRESS
MAY
EARLY SEPTEMBER
EARLY DECEMBER WWW.JAYCASHMAN.COM
MID JULY
EARLY OCTOBER
MID JANUARY
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STERLING EQUIPMENT
UPDATES The “Jay Cashman” Spud Barge
By Mark Quinn One of the primary goals at Sterling Equipment is to expand and improve their already large and expansive fleet. As a result, over the past 12 months they have purchased several vessels and pieces of equipment.
Barges
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330’ x 40’ x 10’ Carfloat Barge 295’ x 56’ x 16’ Deck Barge 240’x 52’ x 10’ Loadline Deck Barge 195 ‘x 34’ x 11’ Deck Barge 180 ‘x 64’ x 12’ Deck Barge 142 ‘x 58’ x 12’ Ex Navy Crane Barge 150’ x 60’ x 10’ Ex Jack-Up Rig 135’ x 44’ x 8’ Deck Barge 130’ x 40’ x 7’ Deck Barge (2) 140’ x 40’ x 9’ Deck Barges (2) 110 ‘x 34’ x 9’ Deck Barges,
Boats
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1800HP Model Bow Tugboat 600 HP 68’ Pushboat 450 HP 40’ Pushboat 44 Passenger Crewboat
Equipment
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Komatsu 1250 Hydraulic Excavator Mantis 10010 50 Ton Tracked Hydraulic Crane (2) Sennebogen 870 Material Handlers American 12220 Clam Shell Crane
This new equipment was purchased to fulfill needs for several upcoming and continuing projects.
New Builds Sterling took delivery of the “Jay Cashman,” a 140’ x 39’ x 9’ Loadline Walking Spud Barge from May Ship in Staten Island, NY. The vessel worked on the Plymouth dredging project then the Chelsea Street Bridge Project and is now working in Dania Canal, FL for Lucas Marine Construction. In August, Sterling took delivery of the “Bobby D” 140‘x 39 ‘x 9’ Loadline Spud Barge. This barge was also built at May Ship. Sterling Equipment contracted with St. Johns Shipbuilding to build the “M.E.R.C Shevlin”, a 267’ x 54’ x 24’ 5,000 cubic yard capacity Loadline Dump Scow. The vessel was delivered in November 2012, and is now the largest Dump Scow in the Sterling dredging fleet.
CASHMAN INK APR 2013
Projects Sterling Equipment is providing complete Marine Support for a Horizontal Directional Drilling (HDD) Gas Pipeline Project between Hoboken, NJ and Manhattan, NY. The project commenced last July and is expected to last until June 2013. Sterling’s contract is $32M and they are working with Michels Directional Drilling and Spectra Energy. During this project, Sterling has utilized numerous barges, cranes, excavators, tugboats and crewboats. The equipment The “M.E.R.C. Shevlin” Dump Scow
Sterling is working with TDC Cranes to convert a Clyde 32 Lift Crane into a Clam Shell Dredge Crane. The crane will have a duty cycle line pull of 200,000 tons at a 75’ Radius and will swing a 70 cubic yard bucket. It will be mounted on a new 180’ x 64’ x 12’ hull complete with two fixed spuds and a walking spud system which Sterling expects to take delivery of in February of this year. Recently purchased were two Former Loadline Oil Barges with the intent of welding the vessels together making one larger permanent vessel. The vessels are currently at GDM Shipyard in Brooklyn, NY where the work has commenced and is expected the last three months. Once the vessel is complete, Sterling will mount their Manitowoc 4600 Ringer on deck. The finished product will be a 270’ x 108’ x 15’ Spud Barge with a 750 ton revolving crane mounted on deck.
Spectra Project platform installation
supports operations which include pile driving, dredging and heavy lift services along with complete marine support. Highlights of the project are installation of a work platform and a pipe pull.
Spectra Projectpipe pullback operations
Oil barge conversion
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Sterling is also working closely with The Demolition Company on the Fore River Bridge Demolition Project in Quincy, MA. They are supplying barges, cranes, excavators, dredges and other equipment to support their operations.
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EMPLOYEE NEWS CONGRATULATIONS! to Glauber De Jesus & his wife on their new baby girl!
Gabriela De Jesus was born on December 20, 2012 at 4:25 AM at 7lbs, 12oz, 19 inches. long.
to Jaclyn Cashman Childs & Trevor Childs on their new baby boy!
to Mike & Jennifer Empey on their new baby boy!
Hudson Cashman Childs
Cooper Empey
was born on December 14, 2012
was born on March 4, 2012 at 9:42 AM at 8lbs, 20 inches. long.
at 6:20 AM at 9lbs, 13oz, 21 inches. long.
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In Loving Memory of Janet Doyle Janet M. Doyle worked for Cashman for more than 15 years. She was a wonderful, hardworking employee and is dearly missed by the Cashman family. We will never forget her unique way of answering the phone, or her bright smile welcoming us to work everyday. Rest in peace Janet, you will never be forgotten.
Bravo! Three Graduations for the DiBona Family
listened to Dario speak rapid-fire Italian with his mother, Dina, and heard vibrant stories of San Donato Val di Comino, the family’s hometown in a tiny village south of Rome.
By Dario DiBona
The entire DiBona family, including sisters Olivia, 17, and Emma, 13, visited the village the past two summers and fell in love with the medieval hillside town. Dario, whose last visit to Italy was in 1974, was reunited with many relatives including his 99-year-old great aunt.
The DiBona family celebrated three graduations this spring. This May, Juliana, 21-year-old daughter of Patti and Dario DiBona, who is a Project Manager at Jay Cashman, Inc., graduated from George Washington University in Washington D.C. with an A.B.A in International Affairs, and minors in English and Theater. Juliana completed her education in three years, graduating Summa Cum Laude with special honors in International Affairs for her senior research paper, which explored the international and domestic factors leading to the current Italian financial crisis. During Juliana’s fall semester before graduation, she studied abroad in Rome, Italy, visiting towns across Italy as well as France, England, and Portugal. She became fluent in Italian and worked as an intern for the Fondazione Adriano Olivetti translating Italian press documents into English.
Olivia, who graduated from Braintree High School in June, began attending the University of New Hampshire in the fall. She plans to major in Justice Studies and minor in Spanish. While at Braintree High, Olivia was an honor roll student and member of the Spanish National Honor Society. She was captain of the BHS varsity dance team, which captured first place at state and New England championships last year. The team also traveled to Florida for a national competition with support from businesses including Jay Cashman, Inc.
The youngest DiBona, Emma, graduated from South Middle School in June and headed to Braintree High School The DiBona daughters. From left to right: Emma, Olivia, and Juliana Juliana, who spent several in the fall. Emma keeps summers working at Cashman, is currently interning for the busy dancing at the Dance Studio of Braintree and recently U.S. Department of Labor in the Office of Child Labor, Forced performed in the Nutcracker and Cinderella ballets. Labor and Human Trafficking. She plans to travel and work for a year before applying to Law School for the fall of 2013. With Dario in New York the GE Hudson River dredging project Juliana’s interest in all things Italian started at her grandparents’ house in South Quincy where she ate authentic Italian meals,
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and her sisters moving on to the next phases of their lives, Emma is enjoying a little quality time with mom.
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FRANK CAMPEA
WELCOME ABOARD! The Cashman Companies would like to introduce some of the new employees who have started over the past year.
RUSSELL VANDIVER Jay Cashman, Inc. | Senior Vice President, Director of Business Development “My wife Mary and I first visited New England in 2003 and fell in love with the place. We are moving from Houston, Texas, and look forward to enjoying the seasons. My interests are travel, cultures of the world and finance, and hobbies include reading, golf and driving country roads.”
“I have been working in the structural, power generation and heavy rigging business for ten years. My expertise includes design, estimating, rigging means & methods and project management.”
MARISA MOOTOO Jay Cashman, Inc. | Receptionist “I enjoy cooking and watching Animal Planet. I’m looking forward to growing with the company and learning as much as I can in the upcoming years.”
ROBERT GOODMAN
ARASH ARBABI
Jay Cashman, Inc. | Vice President , Corporate Development
Jay Cashman, Inc. | Project Scheduler
“I work in the Quincy office supporting Patriot Renewables and I’m looking forward to working with more members of JCI as we move forward. Outside of work, I like to try new restaurants and see live bands perform, and am looking forward to (hopefully) my first Red Sox game in the spring.”
“I work in estimating as part of the project control and proposal development teams. I develop and manage project schedules and assist in proposal preparation. My hobbies are skiing and tennis”
JAMIE MORNEAU
NEAL TWADDEL
Jay Cashman, Inc. | Project Engineer “I’m a project engineer on the Spectra Energy Project in Jersey City, NJ where we provide marine support for the Hudson River HDD crossing. I am a Maine native and enjoy going back up there to visit family and friends. I enjoy exploring new places, painting, drawing and being outside with my dog.”
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Industrial Power Contractors | Project Manager
Cashman Dredging | Field Engineer “Outside of work, I enjoy outdoor activities like hiking, mountain biking, snowboarding, and taking long walks on the beach.”
CASHMAN INK APR 2013
RHONDA RIPLEY Preload Inc. | Administrative Assistant
TIM ASHMORE Jay Cashman, Inc. | Business Development Associate
“I am the Administrative Assistant for the Garland, Texas office. I am married with three daughters, and in addition to working at Preload, I also coach school and competitive cheerleading. I love the beach and any place warm.”
“I work on identifying and pursuing new opportunities for all of the Cashman Companies. My background is in federal Department of Defense contract proposal management and marketing.
JEFF GUERRA
NICK HODGE
Sterling Equipment | Project Engineer
Cashman Dredging | Field Engineer
“I provide administrative, technical, and logistical support on the Spectra Energy Pipeline Project in NY/NJ. I received a Bachelor’s degree in Construction Management from Wentworth Institute of Technology in ’09 and hope to further my education in the near future. Some of my interests include traveling, sports and a variety of outdoor activities.“
“I recently graduated from UMass Amherst. In October, I started working on the GE job in Fort Edward, NY helping out the survey team. In my free time, I enjoy playing sports like basketball and golf.”
MIKE GIBBS
LEIGH-MARIE THORNE
Industrial Power Contractors | Project Manager
Jay Cashman, Inc. | Project Engineer
“I’ve been working in the power generation and industrial business for thirty years. My expertise includes power and process pipe and balance of plant estimating and project management, as well as in the startup and commissioning of systems.”
“I calculate and track all of the rock and sand quantities that are placed on the job and assist with office work. Outside of work I like to hike, mountain bike and ski.”
DOUGLAS CLELLAND Cashman Dredging | Field Engineer / Hydrographic Surveyor “I am currently on the Rockaway Inlet, NY job with the trailing suction hopper dredge Atchafalaya. I hail from New Jersey and graduated with my BS in Ocean Engineering from URI. I enjoy being out on the water whether it’s surfing, fishing or boating, so this job fits me quite well!”
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MICHAEL O’TOOLE Sterling Equipment | Safety Officer “I’m a retired Police Officer and SWAT team member. I enjoy riding my motorcycles. I’m currently at work at the Hudson River Pipeline job.”
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Jay Cashman, Inc. 549 South Street Quincy, MA 02169
FIND US ONLINE
WORK WITH US In a continuing effort to increase the diversity of our work force, we’d like to remind all employees that it is the policy of the Cashman Companies to encourage employees, especially current and minority employees, to recruit qualified women and minorities for employement at our companies. Interested applicants should submit a resume to careers@jaycashman.com and include the name of the employee who referred them.
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