Water Main Expansion

Scope

Melcar was originally contracted to complete four auger bores and two
horizontal directional drill shots under Rt 40 in Bear, Delaware as part of
an ongoing effort to widen the state highway. Once on site, the need for an
additional four auger bores was identified and Melcar was able to quickly
respond and add the scope into a jam-packed schedule to complete the
project on time.

Challenges

Unexpected utilities presented major challenges, with undocumented lines from several providers causing project delays. Melcar quickly coordinated with utility owners and the local One Call team to verify, adjust plans, and safely avoid all existing lines.

Key actions taken:

• Identified and coordinated around unknown utilities
• Allocated additional resources to maintain progress
• Maintained strict communication with all stakeholders

Working on an active state highway added another layer of risk. With minimal buffer space between crews and traffic, the team:

• Stayed on high alert to ensure worker and public safety
• Implemented proactive traffic control measures
• Completed operations without incident

Clear communication, quick adjustments, and a strong safety culture kept the project on track despite the challenges.

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Success Factors/Outcomes

Despite the complexity of the underground conditions and the need to
navigate around existing utilities, our team executed each bore and HDD
shot with minimal disruption and no major setbacks. Coordination between
crews, detailed planning, and the use of advanced equipment allowed us to
stay on schedule and meet all project specifications. The quality of work
and safe execution reflected our team's expertise and commitment to
delivering results under challenging conditions.

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