MANAGING BIOSOLIDS: IS THE U.S. READY?
April 5, 2012
It is fascinating to learn about the engineering marvels that have been developed to give us cleaner drinking water and wastewater. Continue Reading →
April 5, 2012
It is fascinating to learn about the engineering marvels that have been developed to give us cleaner drinking water and wastewater. Continue Reading →
March 16, 2012
Building Information Modeling (BIM) is dramatically changing the way commercial and industrial design and construction is managed and how project teams interact. It involves the creation and use of intelligent, information-rich, 3D models throughout the lifecycle of a building, from design and engineering to construction and facilities management. Ideally, these models are shared and leveraged by all stakeholders to improve the efficiency and effectiveness of design and construction processes.
We strive to use BIM and related technologies wherever possible to improve the construction process from preconstruction through completion. The use of appropriate BIM tools can promote more accurate construction, more efficient processes, and tighter budgets. It can dramatically improve coordination, communication, and cost control as well as improve quality and the overall construction experience.
The challenge with BIM technologies is knowing when and where to use them. Continue Reading →
February 22, 2012
Imagine this: You are planning to start some remodeling work that requires opening up a wall and you’re concerned about what utilities or mechanical systems might be hiding behind the wallboard. Do you consult your as-built plans? Probably, but do you really trust them to be exact? Probably not. What if you could put on your superhero cape and use your X-ray vision? Believe it or not, now you can!
With our PC X-Ray As-Builts™, clients can see behind the walls or above the ceilings in spaces we have constructed. You can be sure of what’s hiding there and not risk the chance of serious or disruptive damage to important building infrastructure.
Here’s how it works: With our panoramic equipment and technology, we can photographically document the systems that will soon be hidden in walls and ceilings. We create a 360-degree interactive image that is both easy to use and accurate. See for yourself:
Click on this image and then move around the screen with your mouse to see beneath the walls and ceilings of this now finished space
Additionally, we have taken the technology a step further by creating an inexpensive virtual window utilizing existing technology. You can step into any room, move the virtual window around the room, and you’ll be looking through a “window” that peers into the wall or ceiling as it was constructed. Dimensionality and locations of piping, conduit, ductwork, and other such items are no longer a mystery.
When installed on a workstation, these images can be linked and navigated either through an index page or with the use of hot spots or buttons in the photos themselves. For example, click on a door and be taken directly to the image of the neighboring room. This can be taken even farther by linking to things such as detailed photos of a particular object. Even equipment operating and maintenance manuals can be integrated. This technology can be tailored to the particular needs of the client or facility management group. With PC X-Ray As-Builts™, the possibilities are almost endless.
February 8, 2012
PC Construction is using iPads in combination with cloud solutions to solve age-old problems in the construction industry.
It has always been a laborious manual task to update drawings and specs with the latest RFIs, design bulletins, and such. Think photocopier, scissors, tape, stacks of blueprints, and volumes of specifications. Now multiply that by each subcontractor having to get copies of each change document and updating their own set of plans and specs. In addition, field personnel need access to a lot of other documents such as shop drawings, current schedules, field sketches, O&M manuals, coordination drawings, safety information such as MSDS, etc.
This situation presents a host of problems. Continue Reading →
December 13, 2011
Struvite is a naturally occurring crystal of magnesium, ammonium, and phosphate. It’s composition is very similar to that of a kidney stone. Imagine millions of these stones in a pipeline, restricting flow and gradually decreasing the inside diameter of a pipe – one can see how this could be problematic. Continue Reading →
September 30, 2011
The Yellow River WRF project team recently completed the work required to process wastewater flow through the final phase of the new plant facilities and began discharging the reclaimed water into the Yellow River. The new plant was put into service in stages over a 21-month period, starting with the new Influent Pump Station in September of 2009 and concluding with the new Membrane Bioreactor (MBR) Facility. The plant is currently processing 10 MGD and producing high quality effluent that is well within its new permit limits. Continue Reading →
July 15, 2011
On June 30, a contract signing ceremony for the Blue Plains Advanced Wastewater Treatment Plant Cambi/Main Process Train construction project was held at DC Water’s headquarters in Washington, DC. In addition to representatives from PC Construction, CDM, and DC Water, attendees included Cambi’s technology director, Merete Norli, who traveled from Cambi’s corporate office in Asker, Norway for this important event.
The $208 million joint venture between PC Construction and CDM is unique in many aspects. It is just the second construction project undertaken by DC Water utilizing the design-build delivery method and it will be the first treatment plant in the United States to incorporate the Cambi thermal hydrolysis process into their facility. At the completion of this project, the Blue Plains Advanced Wastewater Treatment Plant will be the largest thermal hydrolysis process plant in the world.
Engineering and design is underway with construction activities scheduled to begin in January 2012 and completion expected for October 2014.
Click here to read Cambi’s press release.
May 23, 2011
A groundbreaking ceremony was held on May 17 at the Blue Plains Advanced Wastewater Treatment Plant in Washington, D.C. for the $208 million Main Process Train project recently awarded to the PC/CDM joint venture team.
George Hawkins, General Manager of DC WATER, led the events that were attended by a host of local dignitaries including the Mayor of Washington, D.C., the Honorable Vincent C. Gray. Hawkins highlighted that DC WATER is the largest consumer of electricity in the District. The Cambi process, a primary component of the project, will produce combined heat and power capable of generating 13 MW of electricity estimated at $10 million in annual savings. Electricity consumption will be cut by a third when the process is complete. The electricity generated is enough to power 8,000 homes.
Another benefit of the project outlined by Hawkins includes a 50% reduction in solids produced. This will provide an annual savings of over $10 million in trucking costs. Additionally, the plant’s carbon footprint will be greatly reduced as will the amount of total nitrogen released into the Chesapeake Bay.
The Blue Plains Advanced Wastewater Treatment Plant is the world’s largest facility of its kind processing an average of 370 million gallons of wastewater a day. This volume, as described by Hawkins, is sufficient to fill the entire Washington Nationals stadium!
All of us at PC Construction are looking forward to this exciting new project. Stay tuned to the blog for updates along the way!
*On June 1, 2011, we formally changed our company name from Pizzagalli Construction Company to PC Construction Company. Click here to learn more.
March 8, 2011
There are currently four major types of Membrane treatment technologies, one of which is Ultrafiltration Membranes for the treatment of wastewater. Many people have heard of membranes but do not know exactly what they are or how they work.
Ultrafiltration Membranes are similar to the Reverse Osmosis (RO) process utilized in many water treatment and/or desalination plants. For wastewater treatment, the membrane system is installed at ‘the end of the line’ after screening and pretreatment. Effluent is forced through a semi-permeable material, the porosity of which allows inorganic ions to pass, but rejects large organic molecules and colloidal particles. In other words, pollutants are captured but clean water is allowed to pass through. The tricky part is to select the correct membrane material based on the characteristics of the effluent being treated. If the membrane is too porous, the wastewater will not be treated properly. Conversely, if the membrane is too ‘tight’, the result will be extremely clean water but with high energy costs and a material prone to clogging, requiring frequent backwashing and/or chemical treatment.
A simple correlation would be to compare a membrane’s porosity to a common household water filter. For example, if a 2 micron water filter is installed, the result will be extremely clean water that is free of most impurities; however, a great deal of pressure is required to force the water through the filter and can result in very low water pressure at the faucets. If you substitute the 2 micron filter with a 30 micron filter, the result will be increased water pressure at the expense of more impurities passing through the taps. Ultrafiltration Membranes work basically the same way except instead of replacing the cartridges, the filters are backwashed and the solids sent elsewhere for further treatment.
Advantages of Ultrafiltration Membrane treatment may include a smaller footprint requirement for the treatment plant, elimination of secondary clarifiers and tertiary filters, reduction of chemical use, improved water quality, reduced disinfection requirements, and enhanced ability to re-use the wastewater effluent for irrigation. Some disadvantages can include higher energy, maintenance, and membrane replacement costs.
PC Construction has installed numerous membrane systems throughout the country, the largest of which is currently being commissioned at the Yellow River WRF project in Georgia. We are proud to be involved with the adaptation and installation of this technology, continuing to provide the best possible solutions for our client’s needs.
February 10, 2011
A few decades ago, the United States was thought to have an endless supply of phosphorous; however in 2007 we began importing this nutrient. Current estimates place the supply at 1,200 million tons per year and the possibility exists that we could deplete that supply in 25 years.
Phosphorous is both a blessing and a curse. It is one of the key mineral nutrients necessary for plant growth. It stimulates root growth, flower bloom, and seed development. It is an essential component of DNA, RNA, cell membranes, sugars, and carbohydrates. Without phosphorus plants just don’t grow and there is no substitute for it.
On the flip side, too much phosphorous in a body of water stimulates the growth of suspended algae, or phytoplankton. Ever see a nasty, algea-ladened golf course or farm pond? The most likely cause is too much phosphorous.
Wastewater treatment plants receive tremendous amounts of phosphorous in the influent and they are generally required to remove most either biologically or through chemical treatment. Until recently, however, the phosphorous was never ‘recovered’.
Not long ago I was in charge of constructing a design/build pilot plant to test a process called ‘Phosphorous Adsorption’. The results were promising; the levels of phosphorous in the wastewater stream after treatment were virtually undetectable (<.001 mg/l), with the nutrient being recovered as a saleable product for farmers.
The process was fascinating, albeit quite complicated, so a simple explanation will suffice. If you have ever had a water softener you probably know that there are resin beads in the softener tank. These beads hold an opposite charge from the iron in the water. The iron ions cling to the beads, but are released upon a salt water backwash. The Phosphorous Adsorption process is quite similar but instead of the phosphorous ions being washed away and lost, the nutrient is recovered in a filter press. The product can be sold and used as an income stream for treatment plants to defray the costs of the recovery system.
There are always driving forces for new technology. For this to be a viable and economical solution, the nutrient limit regulations must be very low and the cost of phosphorous must be high. I see both occurring in the near future.
January 27, 2011
Over the years, PC Construction has completed a number of successful projects for the Upper Occoquan Sewer Authority (UOSA) in Centreville, Virginia. PC crews are currently in the midst of a $12 million project to upgrade the Chlorine Contact Basins, Primary Clarifiers, and the Activated Carbon Odor Control System. This upgrade project began last August and is scheduled for completion in August 2012.
Most people may look at the below picture and question what it is. Those who have participated in tunnel work would instantly recognize this as the front end of a TBM (Tunnel Boring Machine). And from this perspective, one would know that the TBM has reached the end of its journey. The PC Construction team successfully completed the boring operation for a 66-inch diameter hole over 300 feet in length. Through planning and teamwork, the TBM exited at the arrival point at the correct line and grade. As one of the higher-risk activities on this project, the tunneling portion has been a focus of the early construction activities. The TBM was utilized to bore a hole for a 66-inch casing pipe which will, in turn, serve as the containment pipe for a 48-inch carrier pipe under a roadway embankment. While the photo may not elicit much reaction, it is a very exciting moment to see the arrival of the machine at the other end of a tunnel!
The PC Construction team at the Upper Occoquan Sewer Authority project watch with great anticipation as the Tunnel Boring Machine exits the rock at the correct line and grade after a 300-feet journey
October 18, 2010
What did 250 hospital engineers, facility managers, plant operators, and safety professionals have in common earlier this month? They were all at the New England Health Care Engineers’ Society Annual Meeting in Mount Washington, New Hampshire.
The three-day education seminar, technical exhibit, and networking experience exposed us all to innovative new processes for hospital planning, construction, and utilization. There was healthy discussion around the contractual responsibilities of Integrated Project Delivery (IPD) and Building Information Modeling (BIM). There were several sessions that highlighted simulation technology for determining optimal space needs, bed counts, and surgical services. The panelists even ventured beyond planning and construction into operations and regulatory compliance.
PC Construction was pleased to be selected to participate in a panel discussion on best practices in health care construction estimating and the ideal integrated process for preconstruction. The panel included:
Andrew Martin, Vice President, PC Construction
Eve Norris, Senior Project Manager, PC Construction
Ed Seraydarian, Senior Estimator, PC Construction
Dan Morris, Principal, MorrisSwitzer Environments for Health
Scott LeClair, Principal, Fitzemeyer and Tocci Associates
The topic generated some great questions including, “When we [facility directors] are asked by the hospital’s leadership what three things we will gain by spending money on preconstruction services, what would your answer be?” Collectively, the panel was quick to respond that the project will come in on budget, on schedule, and with a program that will maximize capital dollars.
If everyone attending took away that quick lesson then we’ve done our job well.
Representatives from PC Construction, MorrisSwitzer Environments for Health, and Fitzemeyer and Tocci Associates participated in a panel discussion at the recent New England Health Care Engineers' Society Annual Meeting
October 11, 2010
The strict permit limits set forth by the Department of Environmental Protection’s Chesapeake Bay Initiative has resulted in the need for any treatment plant discharging into waterways leading to the bay to make adjustments to their treatment processes. A main driver of the Initiative is the removal of phosphorus and nitrogen prior to the treated wastewater being returned to the environment. The limits are causing plants to take a closer look at their treatment processes and take on construction projects to reach regulatory requirements.
PC Construction is doing just that with the upgrade and expansion project at the Vint Hill Farms Wastewater Treatment Plant in Warrenton, Virginia. The project includes two main structures. One is the Sequencing Batch Reactor (SBR), which consists of a Precast Post-Tensioned Concrete Structure designed and installed by Dutchland, Inc. Once a base slab was cast, the building of the structure, which includes three separate water-holding areas and one equipment room, took less than a week to assemble. The new process equipment for the SBR, designed by Aqua Aerobics, performs most of the phosphorus removal for the treatment process. We also constructed a Filter Building to accompany the Parkson Dyna-Sand Filters. This structure houses Parkson sand filtration equipment which will be used for the denitrification of the process flow.
This project has achieved a great safety record and is set for completion this month.
Vint Hill Farms Wastewater Treatment Plant
September 21, 2010
One of my passions in life is learning about and implementing measures for conservation of our natural resources. As a kid I spent a great deal of time on the family farm and was intrigued with organic farming and ‘green’ living long before it gained its present popularity. As such, one goal in my new role is to position PC Construction as a leader in the use of the latest technologies for the conservation of electricity, reduction of nitrogen and phosphorous into the water stream, and the construction of carbon neutral water and wastewater treatment plants.
There are many new and fascinating technologies that are being developed and advanced each day. These advances offer additional opportunities for reducing energy consumption and providing clean water for drinking and recreation. Implementation of cutting-edge technology can provide unique challenges and new opportunities to those with the vision and insight to take the first bold step forward. The challenge will be to convince owners and engineers that long-term, sustainable solutions are the most viable alternative means of construction.
No one person can keep up with all the changes and opportunities for future growth in this market. As such, please contact me if you come across new technologies or potential opportunities.
August 20, 2010
Lead has long been recognized as a serious health hazard and, for years, was a common ingredient used in many construction materials, most notably lead paint. The health risks related to lead exposure are particularly serious for young children. In 1977 the use of lead paint was banned in the United States. In addition, OSHA and the U.S. Environmental Protection Agency (USEPA) have strict requirements for contractors who disturb lead paint or materials suspected of containing lead.
Over the years The USEPA and OSHA have continually modified the lead paint standards and requirements. The latest change in the law requires certification for contractors performing lead based paint renovation, repair, and painting activities for all work taking place in housing, child care, and school buildings. While the requirement is restricted to the type of projects listed above, many current PC Construction clients have indicated that certification will be required for all contractors performing work for them.
Even though all lead-related work associated with our projects is subcontracted to abatement contractors, PC Construction is responsible for the proper and safe execution of the work. As a result, our project teams must be aware of safety and disposal requirements associated with lead.
PC Construction has fulfilled all EPA requirements and received certification from the USEPA to perform this type of work. In addition to the certification, ten PC Construction professionals have completed training on disturbance of lead paint. This certification and PC Construction’s efforts to provide associated training goes hand-in-hand with our commitment to ensuring the safety and health of everyone connected to our projects, including those executing the work and those using the completed facility.
August 17, 2010
PC Construction is now live with a customized YouTube channel. The highlight of our channel includes three new videos created to showcase who we are as a constructor of water/wastewater treatment plants, buildings, and facilities, and features our employees’ feelings about our great company.
Check it out at: http://www.youtube.com/pcconstructionco/
July 8, 2010
My objective on the Clifton-Fine Hospital Clinic Replacement and Addition project is clear: deliver the highest quality hospital building within budget and on schedule. One particular challenge we have faced is the project schedule with regard to the limited weather window in the North Country. This issue was addressed during the preconstruction process and, as a result, we researched several alternatives to conventional building systems that are typically constructed on-site. After exploring many options, we settled on a precast foundation and prefabricated wall panels since this approach works well for a building of this size and type. To date the results are very positive. Continue Reading →
June 15, 2010
I recently had the opportunity to join PC Construction Senior Estimator Andy Seaton on a trip to England and Ireland to tour several facilities and learn about a new sludge treatment process being used in Europe and that is expected to be introduced in the United States soon. A Norwegian company, Cambi, developed a Thermal Hydrolysis Process (THP) that takes primary sludge and heats it to approximately 165 degrees Celsius (330 degrees Fahrenheit), resulting in hydrolysed sludge. This process kills all of the pathogens that are found in sludge which makes it suitable for creating a Class “A” Sludge that can be land applied as a commercially saleable fertilizer. It also increases the amount of Volatile Organic Compounds that are released during the digestion process (which increases the amount of biogas that can be produced and used to generate electricity and steam that is used in the THP –while reducing the amount of sludge to be handled) and reduces the mesophilic digestion time (which reduces the size of the anaerobic digesters from those that would be required in a conventional process). Utilization of this process has gradually increased in Europe as many of the technical issues associated with the extreme heat, pressure and caustic environment that are created in the process have been resolved. Engineers are now beginning to recommend the use of the THP at U.S. facilities. Continue Reading →
June 8, 2010
When our $55 million project at the R.A. Thomas Water Treatment Plant first started in November 2008, demolition subcontractors and electricians were on site for the complete demolition of the old plant. Since they had a lot of equipment and people on site, they required that their employees wear high-visibility vests. As demolition finished up and we brought our equipment and people onsite, we decided to institute that same policy. The advantage is obvious. Workers wearing high visibility vests are easier for equipment operators to identify, promoting a safer working environment.
In addition to the bright green vests, we purchased each employee five matching high-visibility t-shirts as an option for hot days or if the vests were uncomfortable. The operators say they can see the employees much better and we are happy to say that our people are safer because of it. We are so pleased by the results that we will take this same policy to our new projects in North Carolina at Rocky River WWTP and Northeast WWTP.
Situated in Winston-Salem, North Carolina, this project will replace the 83-year-old treatment plant for the City and Forsyth County Utilities Commission. This project consists of a new Operations and Chemical Building as well as new Filters, Filter Gallery, Rapid Mix, Flocculation, and Sedimentation Basins. This project also includes a new finished water pump station, two finished water reservoirs, wash water supply tank, wash water equalization basin, wash water clarifier, residuals pump station, and residuals storage lagoons. Construction is anticipated to be completed ahead of the contractual finish date.
Crew members at the R.A. Thomas WTP project show off their high-visibility clothing.
May 11, 2010
April 21 was a tough day for corporate IT Departments who partner with McAfee. Shortly before noon, companies throughout the world faced a full-blown meltdown of computers containing the Microsoft Windows XP operating system after receiving a faulty update from McAfee. The problem was quickly noticed at PC Construction as computers got caught in an endless reboot loop.
Unsure of the problem, our IT team instantly eliminated outside access to the Internet and shut down critical servers capable of transferring viruses. All users were requested to power down their computers while IT tried to figure out what was impacting the PC Construction hardware. PC Construction’s IT team had a solid understanding of what had occurred to not only the PC Construction network system but also to corporations throughout the world within forty minutes. Even though McAfee was not available for assistance, PC Construction began testing solutions to successfully restore the affected computers to their state before the McAfee patch was released. Servers were brought back online in preparation for a controlled restart of network services. Within four hours (and prior to McAfee providing the solution), the entire PC Construction network was back up and running.
Approximately 15% of PC Construction’s computers were infected with the faulty upgrade and all were able to be restored within two full days of the incident using an internally-developed program. Although the incident caused disruption to PC Construction’s business, the situation could have been much worse. I was proud of our team’s effort and success in returning the network back to a full functional state in such a timely fashion.
PC Construction's Information Technology Group
Copyright © 2012
