In January 2023, Earle Asphalt Company broke ground on the New Jersey Department of Transportation's (NJDOT) $86.1 million Route 18, East Brunswick, Drainage and Pavement Rehabilitation Project.
Substantial completion is expected in late 2027 for the initiative that is rehabilitating asphalt pavement, drainage infrastructure, signals and other elements along a 4.14-mi. section of the highway in Middlesex County.
This section of Route 18 has three travel lanes in each direction with no shoulders, a multitude of right-in/right-out connections to driveways and intersecting streets, nine signalized intersections and two closely spaced interchanges at Cranbury and Milltown roads. There are jughandle ramps at each signalized intersection.
NJDOT photo
The drainage system is being constructed to mitigate current flooding conditions and alleviate existing deficiencies throughout the project limits.
"Route 18 is a heavily traveled corridor that serves many local businesses, residents and commuters," said Lizzy Galamba, NJDOT public information officer. "To improve the operational performance of the roadway and ease congestion, adaptive traffic signal technology has been installed at several key intersections on Route 18, including the intersections at Edgeboro Road/Old Bridge Turnpike and Tices Lane. This adaptive technology can detect traffic at intersection approaches and adjust the duration of green light timing, in real time, to improve traffic flow and minimize traffic backups. Additionally, Red Light Extension or ‘Jersey Extension,' Passive Pedestrian Detection and Leading Pedestrian Interval technology have been installed at signalized intersections."
Galamba added the Jersey Extension system uses 360-degree cameras and radar to detect vehicles in the intersection and approaching the intersection too fast right when the signal turns red. If vehicles are detected, the signal remains red for all approaches allowing the vehicle to clear the intersection. This helps mitigate "close calls" and prevent what could be a severe crash.
"Unlike traditional systems that require a person to push a button, the Passive Pedestrian Detection uses the same 360-degree cameras to passively detect pedestrians or bicyclists waiting to cross Route 18 and activates the walk signal," she said. "In addition, the walk signal starts while all approaches remain red. This is called a Leading Pedestrian Interval and gives the pedestrians a few seconds head start to establish themselves in the intersection before parallel traffic gets the green light. These systems have been proven to reduce the number of crashes and fatalities for both vehicles and pedestrians."
Other pedestrian safety improvements include repairs to existing sidewalk, as well as installation of new sidewalk, and upgrading curb ramps to meet ADA requirements. This will create four miles of continuous sidewalk in both directions of Route 18, making the corridor safer and more accessible to pedestrians and vulnerable roadway users. Drainage improvements are being made along the corridor to mitigate flooding events, improving safety and congestion for motorists.
Route 18 was constructed through East Brunswick along its current alignment in 1932. Recent traffic count data estimates 50,000 to 65,000 vehicles travel this corridor every day.
The work zone for this federally funded project covers Route 18 between milepost 35.40 and 39.54, including the Cranbury and Milltown roads interchanges. Additional improvements include guide rail and barrier improvements to meet current Manual for Assessing Safety Hardware (MASH) compliance standards, and upgrades to existing utilities.
The drainage system is being constructed to mitigate current flooding conditions and alleviate existing deficiencies throughout the project limits.
"Longitudinal systems and cross drainpipes are designed [for a] 10-year storm event," according to NJDOT. "Pipes along the roadways that convey runoff from a roadway low point are designed to accommodate a 15-year storm event. The drainage system improvements will reduce the amount of ponding water along the roadway gutters. The resurfacing and reconstruction of the pavement is needed to provide a service life of 10 to 20 years. Deficiencies in the sidewalks, curb ramps, curbs, guiderail and traffic signals, along with missing segments of sidewalk, will also be addressed during construction."
Utility improvements include more than 11,000 ft. of 24-in. gas main being reconstructed, as well as miscellaneous power and telecommunication poles and wires to mitigate project conflicts.
"Most of the utility improvements, primarily the drainage and watermain improvements, were performed by Earle and their subcontractors," said Galamba. "While Earle has also done gas main replacement work, PSE&G is assisting with gas main tie-ins. The utility improvements are still in progress."
Gas mains and connections are being relocated to create space for the new drainage systems and the outdated water distribution system that is being replaced. The project was designed by HNTB.
NJDOT photo
More than 24,000 ft. of 8-in., 12-inch, 16-in. and 20-in. water mains, including all connections and services, are being reconstructed.
"Working around existing utilities proved to be a significant engineering challenge, particularly existing drainage facilities," said Galamba. "The existing drainage system must be maintained until the new system is fully installed and functional, adding design and construction challenges. Additionally, extensive coordination efforts with utility companies during the design phase were necessary to develop plans and minimize construction delays related to the relocation of existing above- and below-ground utilities."
Resurfacing and rehabilitating pavement along Route 18 is estimated to provide a 10- to 20-year service life.
"Although NJDOT does not specify a minimum service life for drainage infrastructure, the new infrastructure will use reinforced concrete pipe, which the U.S. Army Corps of Engineers recommends a design service life of 70 to 100 years," said Galamba.
Earle was awarded the contract in June 2022. Crews have completed the following elements: water main improvements, traffic signal installation and ITS installation. The remaining work includes drainage improvements, curb and sidewalk repairs, gas main upgrades, milling and resurfacing and final striping.
"Some key challenges faced during construction include unmapped utility lines, drainage and other underground features needed to be resolved during construction with additional full-depth pavement reconstruction, relocating existing and proposed features and installing new sanitary sewer service lines to replace existing septic fields," said Galamba. "For example, an abandoned large underground culvert structure was encountered during roadway grading, requiring geotechnical solutions to provide a suitable subbase. An existing 43-inch by 27-inch corrugated metal pipe arch was found to be in significantly deteriorated condition.
"The original design was to reline the metal arch pipe for the regulated waterway," she added. "But due to the condition, the project team rapidly designed a new 24-inch by 38-inch horizontal elliptical reinforced concrete pipe, which was approved by the New Jersey Department of Environmental Protection (NJDEP) as a major technical modification to the Flood Hazard Area Individual Permit."
The project features more than 4 mi. of water mains, 2,400 ft. of duct banks and nine utility poles, which required relocation."
Paving operations, with full reconstruction of the right lane in each direction to correct substandard cross slopes and pavement, were completed in early 2026.
NJDOT photo
The drainage and stormwater improvements are extensive.
The drainage and stormwater improvements are extensive. Earle crews are replacing existing and deteriorated corrugated metal pipes with reinforced concrete pipe that meet current standards, reconstructing 42 lateral drainage crossings and adding four new crossings, replacing longitudinal pipe runs in their entirety, constructing two new bioretention basins one that can hold approximately 1 million gal. and a smaller one that can hold approximately 153,000 gal., reconstructing two wet ponds - 0.8 acres in surface area with a maximum depth of 18 ft. and 0.6 acres in surface area with a maximum depth of 15 ft., rehabilitating one detention basin that can hold approximately 9.2 million gal. and installing three new manufactured treatment devices.
"Most of the drainage infrastructure consists of precast elements that were fabricated off site," said Galamba. "This includes the drainage inlets, manholes, pipes and manufactured treatment devices. Excavation work generally follows OSHA, Utility and NJDOT standards and requirements for depth, width and protection. Deep excavations were provided with timber sheeting."
More than 24,000 ft. of 8-in., 12-inch, 16-in. and 20-in. water mains, including all connections and services, are being reconstructed.
"NJDOT always includes the affected municipality and considers local input during design and construction," said Galamba. "During the design phase, the department held local officials' briefings with East Brunswick township officials, emergency services and other key staff. Additionally, Public Information Center (PIC) meetings were held to gain public feedback on the proposed project. Everyone's input helped shape the project. Throughout design and construction, NJDOT is open and responsive to any public feedback we receive."
More than 150,000 tons of material have been excavated between asphalt, concrete, and soil. New materials that have been brought in include 28,000 linear ft. of drainage pipe; 20,000 linear ft. of gas main; 20,000 linear ft. of water main; 12,500 cu. yds. of concrete; 25,000 tons of dense graded aggregate; 100,000 tons of asphalt; and 10,000 tons of bedding sand.
