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OPERATIONS CENTER EARNS LEED GOLD

April 30, 2012

Yellow River WRF Operations Facility LEED Gold

The Yellow River WRF project team has been co-located at the jobsite designing and constructing for the past five years. During that time the team has achieved some pretty incredible milestones. Earlier this month we were pleased to learn of yet another, accolades that truly speak to the dedication this owner has to its community and the environment. The new Operations Center, which was completed in December 2010, has earned LEED Gold certification by the U.S. Green Building Council. Continue Reading →

TOWER CRANE ERECTED AT DC WATER SITE

April 27, 2012

It isn’t very often we face a need for a tower crane on our construction projects, especially on water and wastewater treatment plants. Yesterday was an exciting day for our crew at DC Water’s Blue Plains Advanced Wastewater Treatment Plant as a tower crane was erected on site. Just 24 hours later, the crane has been load tested and certified and we are now fully operational.

The crane is 166 feet tall with a boom length of 242 feet and a capacity of 6,600 pounds. With a condensed site and high structures, the tower crane is the most efficient equipment to complete the pre-dewatering and solid screening work and will also allow additional access to two of the digester tanks. This is the first of two tower cranes PC Construction will use on this project.

VIRGINIA TREATMENT PLANT PROJECT SHOWCASED AT 2012 DESIGN-BUILD W/WW CONFERENCE

April 27, 2012

On Tuesday, PC Senior Project Manager Dave Johnson presented a case study about Virginia’s first design-build water treatment plant retrofit project at the Design-Build for Water/Wastewater Conference in Phoenix, Arizona. Our design partner, Gannett Fleming and the project Owner, American Water, also participated in this presentation to over 50 attendees.

The focus of the discussion revolved around lessons learned on this type of project, such as:

  • Overcoming permitting hurdles
  • Successes in schedule and cost reduction
  • Challenges associated with the design and construction of parallel but separate treatment trains on a 100-year-old plant
  • The importance of partnering
  • Green practices for construction, including practical applications for utilizing reclaimed materials

The presentation generated great interest as illustrated by the high level of attendance and a lively Q&A session of which I was pleased to moderate. I was also pleased to see more Owners attending this year than ever before. Attendance was the highest ever for this conference, giving strong indications of the increasing popularity and growth of alternative delivery methods.

Click here to check out the presentation.

MANAGING BIOSOLIDS: IS THE U.S. READY?

April 5, 2012

Cecil Mike

It is fascinating to learn about the engineering marvels that have been developed to give us cleaner drinking water and wastewater. Continue Reading →

PWCSA ART CONTEST

February 7, 2012

Mike Cecil, PC Construction Director of Business DevelopmentI had the pleasure of joining PC Senior Superintendent Mike Franzoni on January 31 as a judge for the Prince William County Service Authority Water Art Invitational.

The Water Art Invitational is an annual art contest hosted by Prince William County Service Authority where high school students are encouraged to submit artwork created around a specific theme related to safe treated drinking water and consumption. This year’s theme is “How public water improves the quality of our lives every day.”

This event is one I enjoy participating in for many reasons. It is so important to get the youth of today involved in topics of importance in the world around them. Continue Reading →

PROJECT UPDATE: NORTHEAST WWTP IMPROVEMENTS

January 31, 2012

In May 2010, we were the low bidder on the Northeast WWTP Improvements project in Hickory, North Carolina for the City of Hickory Public Utilities Department. The Notice to Proceed followed in mid-July with construction beginning in August as a result of permitting issues. The project consists of modifications to an existing 6 MGD facility originally built in 1948. The primary scope is to provide a new process train switching from Aeration Basins to Oxidation Ditches, with the addition of a new Influent Pump Station, Grit Removal Structure, Oxidation Ditches, Secondary Clarifier, and SCADA System as well as renovations to the Disinfection Systems, Secondary Clarifiers, Odor Control, and Dewatering Facilities. In addition to the mechanical process construction, a new Laboratory Building is being built.

With no available space on the main 14-acre site for storage or stockpiling, a bridge was constructed across Falling Creek to an adjacent property to allow for material and stockpile storage. This city-owned property has been invaluable to the project. Concrete placement is complete and process piping and equipment are nearing completion for the first phase of the project. The end of the first phase will be highlighted by a night and day operation of nine tie-ins redirecting all incoming flow from the existing process train to the new process train.

Project completion is scheduled for June 2012, six months ahead of the contractual date.

Northeast WWTP

Accumulated Struvite in PipelinePelletized “Prills” for fertilizer

INNOVATIVE TECHNOLOGIES IN WATER TREATMENT PART 3: STRUVITE CONTROL

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 →

Brattleboro Wastewater Treatment Facility Upgrade

PROJECT UPDATE: BRATTLEBORO WASTEWATER TREATMENT FACILITY UPGRADE

November 15, 2011

In September 2010, PC Construction was the low bidder on the Brattleboro Wastewater Treatment Facility Upgrade project located along the Connecticut River in Brattleboro, Vermont. The team received the Notice to Proceed on this $22 million project in December 2010 and construction began in April 2011. The main components of the project include a new headworks building, primary clarifiers, pump gallery, thermophilic digester tank, sanitary pump station, and plant water pump station. The project also includes modification work to the existing secondary clarifiers, dewatering building, digester complex, control building, chlorine building and contact channels, and selector building with a Moving Bed Biofilm Reactor (MBBR) system. Continue Reading →

PC CONSTRUCTION AWARDED DBIA PROJECT EXCELLENCE AWARD

October 25, 2011

At the Design Build Institute of America National Conference in Orlando, Florida, PC Construction employee owners Mike Angeli and Mike Franzoni accepted a prestigious 2011 Design-Build Excellence Award for the $109 million H.L. Mooney WRF Expansion and Upgrade Stage 2, Phase 1 project in Virginia.

To be considered for a National Design-Build Award, projects must demonstrate successful application of design-build best practices as defined by the DBIA Design-Build Manual of Practice. These include early integration of key team members during the proposal process via a proposal charrette or other collaborative outreach efforts and close coordination between design and construction team members from the design development stage through field construction.

The conference opening keynote speaker was the legendary NASA Apollo 13 Commander, Captain James Lovell. Captain Lovell regaled in stories of the ill-fated mission and spoke on how teamwork, collaboration, and ‘out-of-the-box’ thinking all combined to turn an impossible situation into success. Applying these same techniques and skills are crucial to the success of design-build projects.

PC Construction awarded DBIA Project Excellence Award

PROJECT UPDATE: CANAL WATER TREATMENT PLANT

October 5, 2011

The Canal Water Treatment Plant has undergone a number of upgrades over the years, but none included work on the Raw Water Intakes or High Service distributions portions of the plant. PC Construction began work on a new Raw Water Pump Station and the complete renovation of High Service Pump Station #1 in August 2010.

Many of the existing buildings on the plant date back to the early 1900s. High Service Pump Room #1 was built in 1909 and the outside appearance of the building remains just as it was then. Keeping the original appearance of the site buildings was a top priority for the City of Columbia—a challenge considering one existing structure requires renovation and four entirely new structures will be constructed. The team has worked hard to maintain the original historic appearance of the buildings and the result flows nicely with the existing plant structures.

A few of the unique challenges the team faced revolved around what are usually ordinary procedures. One was to construct a cofferdam in the canal that supplies raw water to the plant. Since the canal had been carved out of granite in the late 1800s, accommodations had to be made to the typical cofferdam. With the help of a consulting engineer and a local marine contractor, the team devised a double walled cofferdam that could sit on top of the granite since it could not be penetrated. The space between the two walls was filled with sand, giving the dam the weight required to hold back the water in the canal. The solution proved to be successful, the work is complete, and the cofferdam has been removed.

Another challenge was to create a reliable bypass pumping system that would allow the city to pump the necessary water to their customers while the team completed a very complex distribution piping replacement within the plant. It was also required that the system discharge at 155 psi, adding a layer of difficulty to this portion of the project. The team came up with a plan that would use electric pumps in place of diesel to increase the reliability and cost effectiveness of the system while producing the pressure needed in the system. The bypass system is currently providing water to the city’s distribution lines, allowing for continued progress on the plant piping.

Completion is expected in February 2012, about six months ahead of schedule.

Canal Water Treatment Plant

YELLOW RIVER PROJECT REACHES MAJOR MILESTONE

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 →

DC WATER PROJECTS OUTREACH BREAKFAST

July 28, 2011

Mike Cecil, PC Construction Director of Business DevelopmentI recently had the pleasure of moderating and giving a presentation at an Executive Outreach Breakfast in Washington, DC. The gathering, sponsored by our proposal partner for the Combined Heat and Power (CHP) project, Ameresco, was held to inform local community leaders of potential opportunities for vendors and subcontractors for the CHP project as well as the recently awarded Main Process Train project, both at the Blue Plains Advanced Wastewater Treatment Plant in Washington, D.C. Some of the guests I was able to interact with on a personal level included members of The District of Columbia Building Industry Association, the DC Department of Small and Local Business Development, The Greater Washington Hispanic Chamber of Commerce, and the Prince Georges County Economic Development Department. Continue Reading →

DC WATER CONTRACT SIGNED FOR FIRST CAMBI THERMAL HYDROLYSIS PROCESS PROJECT IN THE U.S.

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.

Click here to listen to Mayor Vincent C. Gray and DC Water General Manager George S. Hawkins discuss construction projects at the Blue Plains Advanced Wastewater Treatment Plant during a press briefing.

DC Water Main Process Train Contract Signing

DESIGN-BUILD DISCUSSION GENERATES BUZZ

June 16, 2011

At the recent Gannett Fleming annual stockholder meeting, Senior Vice President Butch Bedell and I took part in a roundtable discussion and presentation highlighting some important issues associated with the design-build delivery method. Other panel members included industry experts Jack Gallagher, President of American Water, and Bill McGuinness, Executive Vice President of Skanska/USA.

The panel fielded questions from some of the nearly 150 engineers in attendance, with a focus on future trends, ways engineers might improve, and important qualities necessary for the success of design-build projects, to name just a few.

When asked the question “What one piece of advice can you give to improve our future success with design-build,” the panel agreed that selecting the people with the right personality traits is key. This was a bit surprising to some who have never been involved with a design-build project. They imagined success would relate directly to engineering, technical, or organizational skills. Mike added that those skills can be learned, whereas personality traits are inherent. Collaboration, communication, and trust are just as important to the success of a design-build project as are technical aptitude.

Jack Gallagher of American Water stated that design-build has become their preferred delivery method and is now used for the majority of their capital projects. He envisions this trend to continue, and remarked that they do not necessarily select teams based on low cost, but rather on best value, the past history of the engineer and contractor working together, and the ability to function in a collaborative fashion.

Design-Build Discussion Generates Buzz

FIRST 58,000-POUND CAGE SET IN PLACE AT BLUE PLAINS ADVANCED WASTEWATER TREATMENT PLANT

June 14, 2011

PC Construction began installation of the first sections of the slurry wall for the Blue Plains Advanced Wastewater Treatment Plant Contract 1C project in Washington, DC. The slurry wall in this application is used as a cut-off wall between the plant site and the Potomac River to prevent any possible contaminants leaving the site and entering the Potomac River, which boarders the west and south side of the Denitrification Tank. This slurry wall has reinforced-concrete walls which are excavated by a special clam shell bucket mounted to a crane to a minimum depth of 57 feet. The walls are 24 feet long by 3 feet wide. Excluding the four corners there are 70 straight wall panels required to complete this structure.

The slurry walls are constructed by starting with a set of guide walls that are 4 feet deep and 1.6 feet thick. The guide walls are constructed on the ground surface to outline the desired slurry wall and guide the excavation. As the excavation progresses downward, the trench is kept full of slurry to prevent it from collapsing. The outward pressure from the hydraulic head pressure of the slurry and the difference in gravity between the slurry and the surrounding groundwater, keep the trench in place during excavation.

After the desired depth is reached a process called de-sanding is performed, whereby the slurry is cleaned in order to place concrete. Once the de-sanding process is complete a 57 foot tall, 58,000-pound reinforced cage with tie-back trumpets is lowered into the hole followed by 170 cubic yards of tremie concrete. As the concrete is placed in the trench, the slurry is displaced back into holding tanks and ready for the next panel.

In order to meet the tight schedule demands for this project, PC Construction workers and the slurry wall subcontractor are working around the clock in shifts.

First 58,000-pound cage set in place at Blue Plains Advanced Wastewater Treatment Plant

GROUNDBREAKING CEREMONY HELD FOR $208 MILLION DESIGN-BUILD PROJECT

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!

Groundbreaking Ceremony held for $208 Million Design-Build Project

*On June 1, 2011, we formally changed our company name from Pizzagalli Construction Company to PC Construction Company. Click here to learn more.

MILESTONES REACHED AT VIRGINIA BEACH TREATMENT PLANT PROJECT

May 13, 2011

The project team for the Atlantic WWTP Expansion Phase 1 Contract C project in Virginia Beach, Virginia, put into operation the first of four Secondary Clarifiers on April 25. The second clarifier followed into service two weeks later. This work was part of a $5.7 million change order to rehab the plant’s four existing Secondary Clarifiers. Each clarifier is 160 feet in diameter with Siemens clarifier equipment and Warmister fiberglass weirs, baffles, and troughs.

In addition to this milestone, the $3.8 million change order to rehab their existing primary clarifiers was completed on April 21. The work was completed in time for the owner to take on the additional flow from their four other preliminary treatment plants.

BRATTLEBORO OFFICIALS BREAK GROUND ON WASTEWATER TREATMENT FACILITY UPGRADE

April 20, 2011

Tuesday, April 19, marked the official start of Brattleboro’s upgrade construction project at the town’s wastewater treatment facility in Vermont. PC Construction was pleased to join officials and project designers for a groundbreaking ceremony held yesterday.

The $22 million project includes a new headwork’s building, two primary clarifiers, MBBR System, an energy recovery system, and state-of-the art heating and cooling system for the four treatment buildings, as well as technology upgrades to allow the production of unregulated Class-A biosolids as part of the solids treatment process. The project also includes upgrades to the existing secondary clarifiers, sludge dewatering system, chlorine facility, control building, and various yard piping and site pump stations.

Upon completion, the upgrades will allow the treatment plant to run smoother and more efficiently. In addition, the biogas created during digestion will be used to produce heat and power for the facility.

The project is scheduled for completion in August 2012.

Brattleboro Officials Break Ground on Wastewater Treatment Facility Upgrade

Brattleboro town officials, design professionals from Hoyle, Tanner & Associates, and PC Construction team members celebrate the groundbreaking for the $22 million WWTF Upgrade project

PROJECT UPDATE: PERCY D. MILLER WATER TREATMENT PLANT UPGRADE

April 11, 2011

The nearly $20 million project is the first major renovation and expansion to occur at this plant, which was originally commissioned in 1953. The project’s main components include a high-service pumping station, chemical facility, dewatering building, gravity thickener as well as two 1.5 million gallon pre-stressed concrete storage tanks, maintenance storage buildings, a settled residuals pumping station, and a recycled water pumping station. PC has also taken on upgrades to the existing 58-year-old plant, which involves new pumps and screens at the raw water pumping station as well as electrical and instrumentation upgrades. Continue Reading →

INNOVATIVE TECHNOLOGIES IN WATER TREATMENT PART 2: ULTRAFILTRATION MEMBRANES

March 8, 2011

Mike Cecil, PC Construction Director of Business DevelopmentThere 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.

YELLOW RIVER WRF ADOPTS FACILITY LOGO

February 17, 2011

2007, early during the design phase of this $250 million project, Tyler Richards, Deputy Director for Gwinnett County, Georgia Department of Water Resources mentioned that the project should come up with a logo that uniquely represented the project and the team assembled to upgrade the facility. Kristin Wilson, a Field Office Manager for PC Construction, liked that idea. She and a friend who had previously worked together at a graphics design company came up with some ideas and presented them to the entire project team. Everyone was really thrilled with the effort and quickly chose a design that has graced all project correspondence since then. But that wasn’t the end of the story. As the design process for the plant continued, the architect for the project had an idea – why not include this logo on the exterior of each building? So the logo was incorporated into the exterior design of all plant facilities buildings.

For us at PC Construction, that logo serves as a reminder of the incredible work we have put in place on this project. And once we complete construction and move on to our next project, Kristin will have left her stamp behind for many years to come.

Yellow River WRF Adopts Facility Logo

PC Construction Field Office Manager Kristin Wilson poses in front of one of the many plant facilities buildings that boast the Yellow River logo

Yellow River WRF Logo

The logo chosen to represent the Yellow River WRF project

INNOVATIVE TECHNOLOGIES IN WATER TREATMENT PART 1: PHOSPHOROUS RECOVERY

February 10, 2011

Mike Cecil, PC Construction Director of Business DevelopmentA 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.

UOSA TUNNEL SUCCESS

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!

UOSA Tunnel Success

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

‘FLUSH’ TAX?

January 11, 2011

Mike Cecil, PC Construction Director of Business DevelopmentIn 2005, the Maryland General Assembly began assessing a ‘Flush’ Tax on homeowners, even those on septic systems. The tax averages about $30 per year for each household and is being used in part to fund improvements to wastewater treatment plants with the goal of reducing nitrogen and phosphorous discharge into the Chesapeake Bay.

Since that time there have been 16 wastewater treatment plants upgraded and 29 more are in the design or planning stages. We are currently constructing one of the projects funded by the Flush Tax and are excited about the effects these projects are having on the environment and the Chesapeake Bay.

Aside from the Flush Tax instituted in Maryland, numerous wastewater treatment plants in the six-state region that drains into the Chesapeake Bay will also undergo compliance upgrades, further preserving the environment for many years to come.

The future is certainly looking bright thanks to the foresight of various agencies and groups working to preserve the environment. And it is reassuring to know we can each do our part by supporting legislation that encourages environmental stewardship.

ATLANTIC TREATMENT PLANT EXPANSION COMMEMORATED IN VIDEO

December 15, 2010

Mike Cecil, PC Construction Director of Business DevelopmentHampton Roads Sanitation District (HRSD) recently released a video highlighting the expansion to their Atlantic Treatment Plant in Virginia Beach, Virginia.  Take a look and see what our team has been up to and how our combined efforts really are making a difference in the health and well-being of our society! http://www.hrsd.com/atlanticplant.htm

Through a very close relationship with the owner, HRSD, and the design engineer, HDR, PC Construction is nearly complete with this $150 million construction project. This is one of many projects that PC Construction has completed for HRSD, a very progressive and forward-thinking municipality.

When asked what made the project so successful, the team unanimously agrees that it was constant communication between PC Construction, the plant staff, and HDR engineers. Through open and honest dialogue, proper preparation, and contingency plans, the numerous plant shutdowns and bypasses were all completed successfully.

One of the unique features of the Atlantic Treatment Plant is the extensive odor control system.  One can imagine the importance of containing foul odors at a beach town where tourism accounts for a great deal of revenue. A pleasant trip to the beach might not be if such measures were not implemented.

Like every project, whether small or large, success depends on the full commitment of all stakeholders. It is clear that all parties brought their “A” game over the past 3½ years, allowing this project to be completed on time, within budget, and in a safe manner.

LEADERSHIP DEVELOPMENT PROGRAM GRADUATE JOINS TEAM IN NORTH CAROLINA

December 6, 2010

In 2008 Ryan Levesque graduated from the University of Maine with a degree in Construction Management Technology. He had interned with PC Construction during his studies and then signed on to be a member of our team in the Leadership Development Program (LDP) after graduation.

Ryan spent the next few years learning the ropes and completing rotations in estimating, field, office engineering, and scheduling roles at several project sites in the southeast as well as in our regional office in Maine. We are proud to announce that Ryan has successfully completed the program requirements and has graduated, marking his promotion to Project Engineer. Ryan is now a PC Construction employee owner working on the R.A. Thomas WTP Improvements project in North Carolina.

What is the Leadership Development Program? Over 30 years ago, we developed this program to identify and coach future leaders from within the PC Construction team. This program targets energetic, highly motivated employees who strive for excellence and are ready to embrace the demanding expectations of our profession. Emerging leaders receive hands-on training through four vigorous rotations in field work, office engineering, scheduling, and estimating. Each rotation provides a real-world look at each facet of our operations, allowing employees to broaden their understanding of the business and develop a strong foundation for professional growth at PC Construction. This is just one of the ways we support the personal and professional development of our team at PC Construction.

Leadership Development Program Graduate Joins Team in North Carolina

Project Manager Brian Walker congratulates Ryan Levesque, a recent graduate of PC Construction's Leadership Development Program

PROJECT UPDATE: SUBSTANTIAL COMPLETION ACHIEVED FOR $108 MILLION PROJECT

November 30, 2010

On September 30, PC Construction achieved substantial completion on the $108 million H.L. Mooney Water Reclamation Facility Expansion and Upgrade Phase 2, Stage 1 project in Woodbridge, Virginia.  In achieving this contractual milestone, Prince William County Service Authority (PWCSA) was able to request from the Department of Environmental Quality (DEQ) a Certificate to Operate ahead of the imposed December deadline.

This design build project with Camp Dresser & McKee included the upgrade in plant capacity from 18 to 24 MGD, while also reducing the amount of total nitrogen being discharged in accordance with the Chesapeake Bay Initiative.

The increased treatment capacity of the plant was made possible with the addition of a new 95-foot Primary Clarifier, four new Pass Aeration Basins, three 125-foot Secondary Clarifiers a new 95-foot Secondary Clarifier, a new RAS Pump Station, 14 new Denitrification Filters, two covered 85-foot Gravity Thickeners, a new Thickened Sludge Pump Station, and a new SCADA Control System, in addition to upgrades and modifications to existing structures and systems.

Since reaching substantial completion, PC Construction has been awarded a $4 million change order to replace the Odor Control System, modify the Primary Clarifier Influent Distribution Box, and perform site work modifications. We are pleased to continue providing construction services for PWCSA!

H.L. Mooney Water Reclamation Facility Expansion and Upgrade Phase 2, Stage 1 project

PC Construction has reached substantial completion for the $108 million H.L. Mooney Water Reclamation Facility Expansion and Upgrade Phase 2, Stage 1 project

THE CHESAPEAKE BAY INITIATIVE

November 10, 2010

Mike Cecil, PC Construction Director of Business DevelopmentAfter several years of studies and negotiations between the Federal Government and states within the Chesapeake Bay Watershed, a consensus has finally been reached as to the Bay’s “Pollution Diet.”  The U.S. Environmental Protection Agency (EPA) has set annual limits for the amount of discharge into the bay for Nitrogen (187 million gallons), Phosphorous (12.5 million gallons), and sediment (6.1-6.7 billion gallons). 

How does this affect us? Simply put, it is the beginning of an action plan to help clean up the Chesapeake Bay and preserve it for future generations. The states belonging to the 64,000 square mile watershed include Delaware, Maryland, New York, Pennsylvania, Virginia, and West Virginia – as well as the District of Columbia.

The Federal Government has committed $491 million dollars towards the initiative in an attempt to jump-start the program. Some of the monies allocated will be put towards agricultural runoff, storm-water control, wetland conservation, as well as for improvements to wastewater reclamation facilities. Directly affecting our livelihoods will be stricter mandates directed at reducing the amount of phosphorous and nitrogen limits allowed for wastewater plant’s discharge.

There will be many requirements for plant upgrades to meet the stringent discharge limits. This will prove to be good for the construction industry and may provide new and unique opportunities for PC Construction and our industry partners. The first ‘progress report’ of the initiatives’ effectiveness is due in early 2012. Results of this study will determine how much additional funding and legislative mandates may be implemented.

I grew up on the Bay. My father taught me how to go crabbing, fishing, and how to shuck oysters as a young boy. Our family farm is in Saint Mary’s County, Maryland – home of the national oyster-shucking championship. Sadly, the oyster population has been severely reduced to a point where it has not been sustainable – partially a result of the amount of nitrogen and phosphorous released into the Bay from wastewater plants. I am very proud to be in an industry in which we are able to truly make a tangible difference in the quality of life for society.

A UNIQUE PROJECT: UPPER OCCOQUAN SEWAGE AUTHORITY CARBON REGENERATION FACILITY

October 26, 2010

Joe Chaklos, PC Construction Senior Project ManagerOne of the things I love about working for PC Construction is that with each project, there are new challenges and opportunities to implement the latest technologies.

The Carbon Regeneration Facility project is a very interesting project and one of only a few of its kind in the country. The project is yet another in a series of improvements for a PC Construction repeat customer:  The Upper Occoquan Service Authority (UOSA), located in Northern Virginia. 

Talk about sustainability!  This is a fascinating process, a brief synopsis of which is provided below.

UOSA operates an advanced water reclamation plant that processes raw sewage to virtually drinking water quality.  A key component in the overall UOSA process scheme to achieve this challenging goal is the use of Granular activated carbon.  Plant effluent passes through the carbon, which adsorbs organic compounds and other contaminants.  Currently, the UOSA plant has an inventory of 4,000,000 pounds of activated carbon which is used to treat approximately 32 million gallons of water per day. 

Over time, this activated carbon becomes depleted from the contaminants adsorbed and its effectiveness is reduced.  The depleted carbon can be ‘regenerated’ again and again by exposing it to high temperatures which destroy the organics adsorbed by the carbon. The carbon is left intact for continuous reuse in the UOSA treatment facilities. UOSA uses a multiple hearth furnace fired by natural gas for this process to restore (reactivate) the adsorptive capacity of the plant’s activated carbon inventory.

The current construction contract will provide a new multiple hearth furnace, as the existing is reaching the end of its useful life. Once this furnace is operating, major repairs and upgrades will be made to the existing furnace. The combination of projects will provide the owner with reliable regeneration capacity for the foreseeable future. When construction is complete, the plant will be able to produce 12,000 pounds per day of reactivated carbon.

This project provides challenges for close coordination and creativity to construct the new building, carbon furnace, and associated infrastructure while maintaining ongoing operations at this critical facility. Now underway, this project is scheduled for completion in late 2012.

PHOSPHORUS AND NITROGEN REMOVAL SETS TRENDS FOR TREATMENT PLANT CONSTRUCTION PROJECTS

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

Vint Hill Farms Wastewater Treatment Plant

PROJECT UPDATE: BUSH CREEK PUMP STATION

September 28, 2010

As part of the project sequencing for the Bush Creek Pump Station project in Abingdon, Maryland, a 25 MGD full bypass was recently completed. The temporary bypass was needed in order to tie into and modify the pump station’s influent manhole.

Trade Superintendent Tom Youngblood led the charge for the successful series of complicated events necessary for such a task. Tom and his crew started on a Tuesday, with all of the bypass pumps connected and in operation. There were a total of five diesel pumps on hand with multiple piping connections required, ranging in size from 6 to 18 inches in diameter. Wet weather delayed the commencement of the manhole modifications until Friday morning, with the crew completing the work on Saturday. The bypass pumping operation ceased following inspection by the resident engineer on Monday.

It was a difficult week yet the crew did not waiver in their dedication.  That is one of the things I love about PC Construction – knowing that when it gets down to the nitty-gritty and work needs to get done in tough conditions, I’m supported by folks who get the job done right.

There will be other bypass operations for Bush Creek, and I am confident that they too will be completed successfully.

A 25 MGD full bypass in process at PC Construction's construction project at the Bush Creek Pump Station

A 25 MGD full bypass in process at PC Construction's construction project at the Bush Creek Pump Station

SUSTAINABLE SOLUTIONS FOR GROWTH

September 21, 2010

Mike Cecil, PC Construction Director of Business DevelopmentOne 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.

PROJECT UPDATE: ABINGDON WATER TREATMENT PLANT

July 6, 2010

PC Construction completed the construction of the original 10 MGD Abingdon Water Treatment Plant in Abingdon, Maryland, in the fall of 1994. Fifteen years later, we were awarded the $62 million expansion project at this same site. The project broke ground in January of 2009 and consists of the construction of a new 10 MGD treatment train including new raw water screening facilities, pretreatment with rapid and flocculation, clarification using plate settlers, filtration, backwash and washwater recycle, a new 2.5 million gallon clearwell and upgrades to the finished water pumping and existing filters.

The first of three project phases is complete. Phase 1 consisted of the construction of a 115-inch diameter tunnel beneath interstate I95 to carry a new 48-inch raw water main along with a 30-inch and 12-inch finished water service. The requirement to increase the plant’s raw water intake via the tunnel was met two weeks ahead of the contractual date. Phase 2 consists of the construction of the new 10 MGD treatment train. The 20,000 cubic yards of concrete placement is complete with the emphasis shifted to process piping, equipment, and chemical feed systems. Phase 2 construction will be completed three months ahead of the contractual completion date. The final phase, and possibly the most challenging, will be the rehab of the existing filters, filter gallery, and associated controls package. Construction on Phase 3 will not commence until the new treatment train has been placed into service.

Abingdon Water Treatment Plant

PC Construction's $62 million expansion project at the Abingdon Water Treatment Plant

PROJECT UPDATE: ATLANTIC WASTEWATER TREATMENT PLANT

June 29, 2010

PC Construction is in the final start-up phase of the $154 million expansion and upgrade of the Atlantic Wastewater Treatment Plant.  The scope of this project increased plant capacity from 36MGD to 54MGD and thoroughly modernized the facility. Since the start of construction in May 2007, over 690,000 worker hours in the field have contributed to the placement of 47,000 cubic yards of concrete, the installation of 11,000 linear feet of pipe, and top-notch safety performance resulting in two consecutive PC Construction Safety Projects of the Year Awards. The success of this project can be tied directly to a structured partnering process and collaboration among PC Construction, Hampton Roads Sanitation District, and the design engineer, HDR.

Atlantic Wastewater Treatment Plant in Virginia

PC Construction's $154 Million Atlantic Wastewater Treatment Plant Project for Hampton Roads Sanitation District

A TOUR OF SLUDGE TREATMENT INNOVATION

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 →

GOING ABOVE AND BEYOND SAFETY REQUIREMENTS

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.

Going Above and Beyond Safety Requirements

Crew members at the R.A. Thomas WTP project show off their high-visibility clothing.

 

CORBALIS WTP STAGE III EXPANSION PROJECT HONORED BY ASCE-NCS

May 24, 2010

On April 20, the team of Fairfax Water, Camp Dresser & McKee, and PC Construction proudly accepted the 2010 Outstanding Civil Engineering Project of the Year Award by the American Society of Civil Engineers National Capital Section (ASCE-NCS). The award was in recognition of the collaborative effort on the Corbalis Water Treatment Plant Stage III Expansion project in Herndon, Virginia – the largest water treatment plant in the Commonwealth of Virginia.

During the original partnering session, the project team identified a goal of receiving an award for this project. Now, four years, 500,000 cubic yards of excavation, 60,000 cubic yards of concrete, 9 miles of chemical piping, and 100 process tie-ins later, that goal was achieved. Competing against and being selected for this award over outstanding projects like the Capital Visitors Center in Washington DC is something we can all be proud of.

The annual awards banquet recognizes and celebrates local excellence in projects, engineers, and students who have contributed to society and the community.

Corbalis Water Treatment Plant Stage III Expansion Project

Corbalis Water Treatment Plant Stage III Expansion Project in Herndon, VA

PROJECT UPDATE: H.L. MOONEY WATER RECLAMATION FACILITY EXPANSION AND UPGRADE STAGE 2, PHASE 1

May 19, 2010

Over the past 17 years, PC Construction and Prince William County Service Authority have built a solid, successful relationship at the H.L. Mooney Water Reclamation Facility in Virginia. Our first project at this site was awarded in 1993 at a contract value of $34 million. Since that time, we have been awarded contracts totaling more than $150 Million worth of work. Continue Reading →

PROJECT UPDATE: PERCY D. MILLER WTP UPGRADE

May 7, 2010

The Percy D. Miller Water Treatment Plant Upgrade is off to a great start. Part of the upgrade includes the installation of two new 1.5 million gallon pre-stressed concrete tanks. Crom is preparing to start the shotcrete process and should have the first tank completed before the end of June. Last week, Richard Moore, the Project Superintendent, was busy overseeing one of the project’s larger concrete pours at the new High Service Pump Station. During the course of one day, Richard and his crews placed 240 yards of concrete, bringing the concrete work to over 25% complete.

Percy D. Miller WTP Upgrade Project

PC Construction's upgrade project at the Percy D. Miller WTP in Middletown, VA

$147 MILLION TREATMENT PLANT PROJECT ACHIEVES SUBSTANTIAL COMPLETION

April 16, 2010

On March 29, PC Construction achieved substantial completion on the Atlantic WWTP Expansion Phase 1 Contract C project in Virginia Beach, Virginia. The project team turned the valve on the Raw Water Influent line on April 12 and flow was introduced into the new Headworks, Primary Clarifiers, Aeration Basins, Secondary Clarifiers, RAS Pump Stations, and the Solids Handling Building. The extremely complex Odor Control Facility also went online at the same time. The construction of this project increases the plant’s treatment capacity from 36 to 54 MGD.

This project included the expansion and upgrade of the existing wastewater treatment plant for Hampton Roads Sanitation District, including new aeration tanks, blower and electrical building, dewatering building, chlorine contact tanks #3 and #4, digested solids storage tank pump station, acid phase digester, odor control station, primary clarifiers #5 and #6, plant drain pump station # 2, primary treatment facility, secondary clarifiers #5 and #6, solids handling building, cake storage pad #2, and miscellaneous distribution boxes and ancillary facilities. Work also included modifications and upgrades to existing chlorine contact tanks #1 and #2, effluent pump station, primary clarifiers, digesters, solids handling, and generator room.

This project also received the PC Construction Safety Project of the Year Award in the Over 75,000 Hours Category for 2007 and 2008.

$147 Million Treatment Plant Project Achieves Substantial Completion

A recent aerial of the Atlantic WWTP Expansion project in Virginia

AIRPORT PARKWAY WWTF UPGRADE GROUNDBREAKING

April 12, 2010

On Wednesday, April 7, city officials and representatives from PC Construction, Hoyle, Tanner & Associates, and Airport Parkway WWTF celebrated the start of construction on the $22 million upgrade of the 44-year-old facility. The upgrade will increase the treatment capacity from 2.3 to 3.3 MGD and consist of an upgrade and expansion to the headworks, primary, biological nutrient removal, secondary, filtration, disinfection, sludge digestion and miscellaneous handling facilities. The proposed improvements will replace existing inefficient equipment with new highly efficient equipment to lower power consumption and will use biogas from the digestion process to fuel a cogeneration unit to heat and power the plant. The project is scheduled for completion in November 2011.

Airport Parkway WWTF Project Breaks Ground

Airport Parkway WWTF Project Breaks Ground