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January 27, 2025

General Contractor Highway/Civil under 500K hours

Photo courtesy of Orion Marine
For the Port of Seattle’s Terminal 5 modernization, the Orion team maintained 100% participation in the Job Hazard Analysis observation program, and four project leaders were awarded safety recognition pins by the Port of Seattle.

Orion Marine

Over the past three years, Orion Marine has successfully managed diverse and complex projects posing unique safety and operational challenges while exemplifying the company’s adaptability in large-scale construction. Below are three key projects that illustrate Orion’s ability to overcome these challenges while maintaining a strong commitment to safety.

Vigor Shipyard NRD Habitat Restoration Project

This project transformed a contaminated industrial site into a thriving aquatic habitat for juvenile salmon. A unique challenge in marine construction is the “fish window,” a restricted period during which companies can work in-water to protect migrating fish. This window, typically during the worst weather months, requires crews to work long hours around the holidays, with limited time off. Despite these pressures and over 140,000 man-hours worked, the team had only one minor recordable incident during the punch list phase.

The project involved the demolition of old structures, including a pier and shipway, and the pulling of 4,300 creosote-treated piles — tasks fraught with unknown hazards. Diligent planning and the strategic use of machinery helped keep people out of harm’s way while ensuring the project’s success.

Port of Seattle Terminal 5 Modernization

This project modernized a key terminal to handle ultra-large container ships, significantly enhancing the region’s shipping capacity. The job involved driving over 2,100 piles, including 350 that were 24 inches in diameter and more than 180 feet long. Seismic requirements and environmental restrictions, especially around underwater work, added to the complexity. Safety remained a top priority, with 100% participation in the Job Hazard Analysis (JHA) observation program. Four project leaders were awarded safety recognition pins by the Port of Seattle Safety Leadership Group in 2023.

In addition to the piling work, the team tackled a large stormwater upgrade project, which required setting 24 deep precast concrete stormwater structures, with 13 of them involving complex bypass systems to manage existing stormwater flows. The deepest excavation reached 27 feet, influenced by tides and a high-water table. The team safely handled the discovery and disposal of 20,000 tons of contaminated soil without incident.

Pearl Harbor Naval Shipyard Dry Dock, Hawaii

Part of the Navy’s Shipyard Infrastructure Optimization Program (SIOP), this project involved driving 84-inch piles to create Dry Dock 5, which will support the U.S. Navy’s Pacific Fleet. The dry dock, designed to accommodate Virginia-class submarines, presented significant technical challenges, particularly in a marine environment with strict seismic and environmental regulations. The work requires precision and adherence to rigorous safety protocols to ensure the long-term viability of this $2.8 billion infrastructure upgrade.

Each of these projects highlights Orion’s ability to navigate challenging environments and conditions while prioritizing safety and delivering high-quality work.


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