Shipping Lock Project Cost Reduced in Sault Ste. Marie

News Summary

The estimated cost for the new shipping lock project in Sault Ste. Marie has been cut by nearly 10%, now at approximately $2.62 billion. This reduction is attributed to the elimination of contingency expenses, with significant construction progress already made. The project is essential for U.S. supply chains, particularly for transporting iron ore. Thus far, over $630 million worth of work has been completed, and the project is expected to be finished by summer 2030.

Sault Ste. Marie – The estimated cost for the new shipping lock project in Sault Ste. Marie has been reduced by nearly 10%, now standing at approximately $2.62 billion, down from the initial estimate of $2.9 billion. This reduction was reported during a stakeholder presentation by the U.S. Army Corps of Engineers.

The update was provided by Kevin McDaniels, deputy district engineer for planning programs and project management within the Detroit District of the Corps. The decrease in cost is largely attributed to the elimination of contingency expenses, as all contracts for distinct sub-phases of the project have already been awarded, resulting in an estimated savings of around $250 million in risk.

Construction of the new lock is on track for completion by the summer of 2030. To date, the project has secured a total of $2.321 billion in funding, with an additional $176 million proposed for the 2026 fiscal year budget by President Donald Trump. Furthermore, an estimated $103 million will be necessary for ongoing construction activities during the 2027 fiscal year.

Significance of the Shipping Lock Project

The new shipping lock will measure 1,200 feet in length and is designed to replicate the Poe Lock, which currently serves as the only lock capable of accommodating the largest Great Lakes freighters. The shipping complex is crucial to the U.S. supply chain for steel, facilitating the transport of iron ore from Lake Superior to steel mills situated along the lower Great Lakes. A failure of the Poe Lock could disrupt this supply chain, potentially leading to an estimated 11 million job losses and imposing a staggering $1.1 trillion economic impact.

Current Phase and Achievements

The project is currently in its third phase, which is focused on constructing the new lock chamber. To date, over $630 million worth of construction work has been completed. Recent achievements include the successful completion of a new bridge connecting to the existing power plant, the demolition of the aging Sabin Lock structure, and the erection of a third tower crane on-site. These newly constructed tower cranes, with heights ranging between 240 and 270 feet, are among the tallest structures in Michigan’s Upper Peninsula.

Ongoing Construction Efforts

A comprehensive ship simulation study was conducted to verify the design of the new lock, prompting the extension of the north upstream approach wall and the inclusion of timber fenders. Contractors have been actively involved in bedrock excavation using advanced hydraulic machines known as “hoe rams.” The plan includes constructing a total of 81 monoliths, which are large concrete blocks that will form the walls of the new lock. So far, over 50 monoliths have been initiated, with one block fully completed.

Notably, the concrete being utilized for this project is specifically engineered with heavy aggregate, offering durability distinct from traditional concrete used in similar applications.

Recent Developments in the Shipping Season

The 2025 Great Lakes shipping season commenced with the reopening of the Soo Locks on March 21, ahead of schedule. The Poe Lock had been closed for maintenance and repairs since January 16 as part of routine winter upkeep, which included various repairs and rehabilitation work on upstream stop log recesses performed by Kokosing Industrial Inc. at a cost of $2.7 million.

The locks themselves play a vital role in enabling vessels to navigate a 21-foot elevation drop in the St. Marys River, linking Lake Superior with lakes Michigan and Huron. Each year, vessels make over 4,500 trips through the Soo Locks, transporting approximately 80 million tons of cargo, primarily iron ore, coal, wheat, and limestone.

Deeper Dive: News & Info About This Topic

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