Power Cable Manufacturing Facility Stabilization Project

Background

LS GreenLink is a landmark infrastructure project in Chesapeake, Virginia. It represents a $700 million investment to build the largest submarine power cable manufacturing facility in the United States. Spanning nearly 100 acres, the site will produce high-voltage undersea cables essential for offshore wind farms and long-distance energy transmission. The facility includes what will become the tallest building in Virginia and stands as a cornerstone of the region’s clean energy and industrial future.

Before vertical construction could begin, the site needed extensive ground preparation to support the planned foundations and equipment loads. Nearly 2,000 drilled shafts were required, including 325 positioned beneath the cable winding structure. The existing soils had to be stabilized to ensure long-term performance. The size of the foundation system and the volume of work across the site demanded a methodical and consistent approach to maintain progress and meet engineering requirements.

The Challenge

The LS GreenLink site required consistent stabilization to meet engineering specifications. Lime treatment depths ranged from 2 to 4 feet, depending on the underlying soil profile and structural requirements. The installation of nearly 2,000 drilled shafts demanded precise coordination with concrete and rebar placement. The site was constantly active with 8 drilling rigs operating alongside cranes used for rebar cage installation.

Sequencing excavation, treatment, and backfill operations required careful planning to avoid delays and maintain progress across multiple trades. Early in the project, conditions were so poor that crews struggled to move equipment across the site. As one team member put it, “we couldn’t even drive off the pad until we started using lime.” This effort required close coordination not only among drilling and stabilization crews but also with Barnett Southern, the grading contractor responsible for moving and managing the raw and treated material across the site – ultimately handling nearly 1.2 million cubic yards of soil.

The Solution

In early July, Site Prep Inc. of NC was brought in to evaluate stabilization options. While many were considering cement, the team quickly identified the soil on site as one more conducive to lime treatment based on field observations and experience. That insight proved pivotal. Site Prep Inc. of NC implemented a full-site lime treatment program that transformed the entire subgrade.

Quicklime was applied at a rate of 27 lb/SY, which equated to approximately 3% by weight (assuming a soil unit weight of 100 pcf). The soil was excavated, treated with lime, and replaced to create a uniform, engineered fill across the entire site. A lane-by-lane sequencing method allowed treated material to be moved from one section to the next, enabling continuous progress and minimizing disruption. Rebar cages were fabricated off-site and transported in, reducing on-site congestion and fabrication costs. Beneath the cable winding zone, dual-diameter cages and 2 to 3 inch all-thread were installed to meet the project’s demanding structural specifications.

Implementation

Lime treatment was performed across the entire site to depths ranging from 2 to 4 feet. Each drilled shaft required between 16 and 17 cubic yards of concrete, typically delivered by 2 to 3 trucks per hole. The 8 drilling rigs worked in tandem with cranes that supported both drilling operations and rebar cage placement. Drilling and concrete operations were closely coordinated with the stabilization team to maintain momentum and avoid bottlenecks. The scale of the site and the number of moving parts required constant communication and precise sequencing to keep the project on track.

Results

The lime stabilization strategy delivered both technical success and significant cost savings. Treated soils provided a stable base for deep foundations and heavy equipment, allowing the project to move forward without the need for costly remove-and-replace operations. The sequencing approach enabled continuous progress acrosstrades, minimizing downtime and keeping the schedule on track.

One of the most immediate returns came from the use of a storage PIG – a mobile tank trailer used to store dry bulk lime. By having material staged on-site and ready to go, Site Prep Inc. of NC was able to maintain uninterrupted production without waiting on deliveries or risking supply delays. The ability to keep crews working continuously translated into major cost savings. In fact, the value of having lime available when and where it was needed covered the equivalent of a couple of months’ rent in just one day.