Construction of the New Lock at the Soo has reached a major milestone, with Phase 3 of the project now 50% complete.
The U.S. Army Corps of Engineers awarded the Phase 3 base contract in July 2022 to Kokosing Alberici Traylor (KAT) LLC, a joint venture that includes Traylor Bros., Inc. To date, KAT has completed approximately $975 million of work on the project.
As part of the joint venture, the Traylor National Heavy Civil Division team is currently focused on mass concrete placement for the lock walls and floor, construction of the new pump well, and offsite fabrication of major steel components including miter gates, ship arrestors, and culvert valves. Approximately 400,000 cubic yards of concrete will ultimately be required to complete the new lock, with more than 140,000 cubic yards placed through August.
Phase 3 includes demolition of the existing Sabin Lock, bedrock excavation, construction of the new lock chamber walls and floor, fabrication and installation of miter gates, installation of mechanical and electrical systems, rehabilitation of the downstream approach walls, and construction of a new pump well.
The project has also become a strong example of collaboration across Traylor Construction Group, with Ballard Marine Construction, Triad Fabricators, and Sterling Industrial contributing specialized capabilities to the work.
Ballard’s Robotics and Survey Division performed an ROV inspection of the South Poe Lock wall to identify conditions that could affect installation and sealing of a limpet dam. The team also captured more than 310,000 images to develop a detailed 3D model of the wall, providing centimeter-level accuracy to support design and work planning.
Triad Fabricators is producing critical steel components for the project, including primary and secondary anchorages for the miter gates, quoin blocks, culvert valve embeds, bulkhead embeds, and intake screens.
Sterling Industrial is supporting the Shaft 6 Electrical Project through installation of new conduit duct bank systems, a service bridge within the existing hydroelectric power plant, and power and control cabling serving the Shaft 6 Maintenance Building. Their scope also includes specialized medium-voltage work in the deep service tunnel approximately 100 feet below grade.
The $3.219 billion New Lock at the Soo project will add a second Poe-sized lock to the Soo Locks facility, increasing resiliency at one of the nation’s most important commercial navigation corridors. The existing Poe Lock currently supports 88% of U.S. domestic iron ore transportation, making the facility critical to American steel production and the domestic supply chain.
The project remains on schedule for its targeted 2030 completion despite the challenging conditions of Michigan’s Upper Peninsula.