ALABAMA STATE EDITION
231
65
72 Florence
2
Huntsville
20 Decatur
72
565 59
43
A Supplement to:
231
431
31
5
Gadsden
78 59 Anniston
20
Birmingham Bessemer
82 Tuscaloosa
65 280
20 82 Auburn
80
85
Selma
Phenix City
Montgomery
82
December 12 2012 Vol. XXIV • No. 25
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“The Nation’s Best Read Construction Newspaper… Founded in 1957.”
Dothan
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Mobile
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Your Alabama Connection • Rich Olivier, Atlanta, GA • 1-800-409-1479
Shades Mountain Filter Plant Receives Improvements By Cindy Riley CEG CORRESPONDENT
After three years, major improvements to the Birmingham Water Works’ century-old Shades Mountain Filter Plant in Birmingham, Ala., are now complete. In August 2009, general contractor B.L. Harbert International LLC (BLHI), began work on the facility, which is located off Highway 280 just three mi. south of downtown. Construction on the $41 million project was finished in June 2012. “The plant needed to increase its storage capacity and upgrade its existing pumping system to comply with updated state and federal regulations. It varied throughout the duration of construction, but the maximum number of personnel on site was around 125 at one time,” said Jeremy Pipkin, LEED AP with BLHI. Pipkin said the objective of the Phase II upgrade project at the plant is to increase the water storage capacity of the plant by 600 percent, while consolidating pumping operations and upgrading electrical systems for the entire plant. This will add two six-million-gallon pre-stressed concrete clearwells, a transfer pump station, a finished water pump station, a new electrical building and a new lime treatment facility. A total of 16 horizontal split case pumps and three vertical turbine pumps will be added to the plant, which will replace the plant’s older pumps that are spread throughout the campus. The project also adds approximately 7,000 linear ft. (2,133 m) of large diameter ductile iron pipe ranging from 24 to 60 in. (61 to 152 cm) in diameter. This new pipe ties into the existing lines of the system in 19 different tie-in locations. A majority of the existing lines are between 50 and 100 years old and require tie-in with custom fittings to tie ductile iron pipe to cast iron lines and concrete cylinder pipe with no existing means to stop the current flow. Different methods are utilized to temporarily stop the flow to allow the tie-ins to occur. In some cases line stops were utilized to facilitate this and in other cases divers were sent into the
Excavation for 60-in. (152 cm) ductile iron pipe.
Main service line tie-in.
Photo courtesy of B.L. Harbert International LLC
existing operating clearwell to plug the lines exiting the clearwell. “The biggest challenge was working around the existing piping and structures of the 100-plus-year-old facility,” said Pipkin. “We had to make certain to protect existing piping while installing the new 28-feet deep transfer pump station. We were also tying in to several existing pipes in the system where flow needed to be stopped prior to the tie-in work commencing. We accomplished stopping flow by utilizing line stops in some cases. In other cases we put divers in the existing clearwell to perform camera observation of the lines. After we observed the lines we knew which ones to plug to stop flow. We also had to make certain that our actions onsite did not affect the distribution service since the system for the city relies on several different filter and pump stations to balance the supply of water to customers.” Pipkin continued, “We used equipment from mini-excavators to D-10 dozers and litsee PLANT page 6
Photo courtesy of B.L. Harbert International LLC
Page 2 • December 12, 2012 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
Montgomery • Jefferson • Talladega • Calhoun • Russell • Walker • Lawrence • Dekalb • Morgan • St. Clair • Tuscaloosa • Morgan • Shelby •Alabama Bibb •Hale • Fayette • Marion • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • St. Clair • Chilton • Escambia• Montgomery • Jefferson • Russell • Fayette • Conecuh • Coffee • Geneva • Montgomery • Jefferson • Talladega • Bibb • Coffee • Calhoun • Russell • • Walker• Lawrence• Dekalb • Morgan • St. Clair • Tuscaloosa • Bibb• Hale • Fayette • Monroe • Clarke • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • Montgomery • Jefferson • Talladega
‘The Yellowhammer State’ Highway Project Lettings
The Alabama State Department of Transportation received bids for transportation-related improvement projects. Following is a list of some of the projects let. County: Autauga Contract ID: NHF-0006(535). Project: Additional lanes (grade, drainage, pavement and signals) on SR-6 (U.S.-82) from near SR-206 to SR-14 in Prattville. Distance: 2.407 mi. Contractors and Bid Amounts: • Wiregrass Construction Company Inc. — $4,634,058 • Chilton Contractors Inc. — $4,935,446 • Apac Mid-South Inc. — $5,307,073 County: Limestone Contract ID: IM-I565(310). Project: Micro-milling, resurfacing and traffic stripe on I565 from MP 5.13 to MP 7.025 in Huntsville. Distance: 5.22 mi. Contractors and Bid Amounts: • Good Hope Contracting Company Inc. — $1,179,219 • Apac Mid-South Inc. — $1,213,027 • Wiregrass Construction Company Inc. — $1,217,602 County: Baldwin Contract ID: ACBRZ58314-ATRP(001). Project: Bridge replacement and approaches on CR-134 (Truck Route 17) at Hollinger Creek southwest of Gateswood. Distance: .40 mi. Contractors and Bid Amounts: • McInnis Construction LLC — $1,828,706 • Murphree Bridge Corporation — $1,965,596 • Gulf Equipment Corporation — $2,039,959 County: Henry Contract ID: ACNU58228-ATRP(001). Project: Resurfacing and traffic stripe on CR-65 from SR95 to SR-10 in Shorterville. Distance: 7.23 mi. Contractors and Bid Amounts: • Apac Mid-South Inc. — $1,002,550 • Wiregrass Construction Company Inc. — $1,034,262 County: Autauga Contract ID: ACNU58333-ATRP(001). Project: Resurfacing and traffic stripe on CR-1 from SR14 near Burnsville to SR-6 (U.S.-82) near Billingsley. Distance: 14.11 mi. Contractors and Bid Amounts: • Asphalt Contractors Inc. — $1,946,848 • Wiregrass Construction Company Inc. — $1,948,857 • Apac Mid-South Inc. — $2,069,844 County: Houston Contract ID: ACNU58539-ATRP(001). Project: Resurfacing and traffic stripe on CR-69 and CR-
77 (South Rocky Creek Road) from Hickory Grove Road to U.S.-84 east in Ashford. Distance: 11.84 mi. Contractors and Bid Amounts: • Apac Mid-South Inc. — $1,926,644 • Wiregrass Construction Company Inc. — $2,073,367 County: Covington Contract ID: ACNU58543-ATRP(001). Project: Resurfacing and traffic stripe on CR-70 from CR49 to CR-77 northeast of Andalusia. Distance: 7.51 mi. Contractors and Bid Amounts: • Wiregrass Construction Company Inc. — $1,025,619 • Apac Mid-South Inc. — $1,143,316 County: Mobile Contract ID: BR-0213(501). Project: Bridge replacement and approaches on SR-213 at Norton Creek in Saraland. Distance: .05 mi. Contractors and Bid Amounts: • Murphree Bridge Corporation — $831,111 • Remedial Services Inc. — $939,034 • Gulf Equipment Corporation — $1,001,490 County: Mobile Contract ID: EB-0016(510). Project: Planing, resurfacing and traffic stripe on SR-16 (U.S.-90) from SR-163 to Broad Street and on SR-42 (U.S.-98) from Broad Street to the Bankhead Tunnel in
Mobile. Distance: 2.94 mi. Contractors and Bid Amounts: • Hosea O. Weaver & Sons Inc. — $962,951 • Mobile Asphalt Company LLC — $969,804 • John G. Walton Construction Company Inc. — $1,076,087 County: Morgan Contract ID: NH-HSIP-0067(505). Project: Planing, resurfacing, traffic stripe and bridge rail retrofit on SR-67 from north of CR-161 (Indian Hills Road) (MP 35.570) to SR-3 (U.S.-31) in Decatur. Distance: 3.38 mi. Contractors and Bid Amounts: • Reed Contracting Services Inc. — $1,604,057 • Wiregrass Construction Company Inc. — $1,664,773 • Joe Keenum Excavation & Construction Inc. – $1,971,620 County: St. Clair Contract ID: STPAA-HSIP-0025(533). Project: Planing, resurfacing and traffic stripe on SR-25 (U.S.-411) from north of CR-10 (MP 174.330) through Branchville to CR-272 (Maddox Farm Road). Distance: 9.56 mi. Contractors and Bid Amounts: • Good Hope Contracting Company Inc. — $2,796,949 • McCartney Construction Company Inc. — $2,804,090 • Apac Mid-South Inc. — $2,899,778
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • December 12, 2012 • Page 3
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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • December 12, 2012 • Page 5
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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • December 12, 2012 • Page 5
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Keeping Old System Online, Large Amount of Rock Prove Challenging PLANT from page 1
erally everything in between to clear and excavate the land. We utilized trackhoes (PC-400’s), D-5 dozers, and sheepsfoot compactors to install the piping. We also used specialized line stopping equipment to stop flow to the lines as well as trench boxes to perform safe excavations. The topography of the site did not allow for access to all areas so a 100-ton LinkBelt crawler crane was utilized for setting formwork and roof trusses. Approximately 5,700 cubic yards of concrete and 7,000 linear feet of large diameter ductile iron pipe also were used.” Weather did not play a significant role, but crews did encounter a large amount of rock that made excavation more challenging at times. Pipkin said the most time- consuming task was the main line tie-ins, because of the investigative and exploratory time needed to mitigate potential risk exposures. The new additions will not drastically change the way the plant currently functions, but it will ensure that the owner meets or exceeds the latest state and federal regulations as well as providing reliable pumping operations to serve customers for several years to come. According to Project Engineer Brandon Lawhern of Gainesville, Fla.-based The Crom Corporation, “Crom was the designer and constructor of the prestressed concrete tanks and its accessories in their entirety. This in detail was two 6.0 MG Prestressed Concrete Clearwells with internal circular baffle walls. “We were required to cast two 185-ft. (56 m) diameter slabs 6-in. (15 cm) thick and constructed two sets of five ring baffles using shotcrete, a pneumatically applied concrete. Then we set a steel diaphragm shell for the exterior tank wall and applied shotcrete to the inside and exterior surface of this diaphragm shell. We then cast two free-span (not column supported) concrete domes. Once this was completed, we prestressed the entire tanks, which causes the tank to remain in constant compression and supports the concrete domes. A thin layer of shotcrete is applied to the exterior surface of the tank wall to protect the prestressing wires wrapped around the tanks.
Finally, we painted the exterior of the tanks to get them to final form.” “Concrete work is highly dependent on favorable weather, and the weather through the winter served many challenges in an effort to complete the work on schedule,” Lawhern added. “More than 6,000 cubic yards of concrete was used to construct the tanks which is more than 410 concrete trucks, along with a crane to move shoring and miscellaneous items, a prestressing rig to pull the prestressing wire at 3,000 PSI around the tank. There was more than 24 miles of wrapping of the tanks with this wire, along with multiple loaders, large air compressors and special equipment.” Materials included 231.4 tons (209 t) of reinforcement steel, 68.4 tons (62 t) of prestress wire — not including bolsters and 1,370 gallons of paint. As much as 2,066 cu. yds. (1,579 cu m) of concrete was needed for the floor, 878 cu. yds. (671 cu m) for the dome and 3,586 cu. yds. (2,741 cu m) for grout. “The job lasted from May 2010 through July 2011. Crom’s primary directive is to provide a low-maintenance, long-term design and approach to water storage so that owners are able to keep rates low so that maintenance issues are not a large factor in the service they provide to their clients.” Other subcontractors on the project included Furmanite, which was responsible for the linestops, and Stone and Sons Electrical. Stone and Sons, which specializes in water, wastewater and industrial projects, assisted the owner, engineer, general contractor, plant management and various vendors in dealing with equipment layouts, process equipment integration and project scheduling. It also coordinated with the power company for the double feed to the plant. Work began in September of 2009 and finished in July 2012 “Our scope for this project was large and complicated,” said Project Manager Danny Baker. “There was the typical furnish and install of all electrical equipment, raceways, and wiring consisting of medium voltage, 600 volt and low voltage, but we also
furnished and installed all instrumentation including, but not limited to, transmitters, gauges, switches and flow meters and related items. We provided new medium voltage substations, wiring and terminations, installed new SCADA equipment complete with the fiber optic backbone for the communication to the plants existing system and integration of the two SCADA systems. Additionally, the security fencing and mow strip was included in our scope, as well as furnishing the raceway and poles for the security and site surveillance. “One of the biggest challenges was to keep the existing power system for the plant online while the new system was installed and tested,” Baker continued. “The systems had to be paralleled so we could change over all existing building feeders and process equipment to the new system and have each maintain the capability of the backup power. There was no margin for error in that any issues could have resulted in plant interruption and BWWB customers not receiving water service.” The Birmingham Water Works Board (BWWB) oversees one of the top five water systems in the nation, and is the largest water utility in the state, serving more than 600,000 customers in Jefferson, Shelby, Blount, St. Clair and Walker Counties. The filter plant Phase Two project is being implemented to comply with Alabama Department of Environmental Management regulations. Considered a major capital improvement project that involves new piping, electrical upgrades and a new transfer pump station, it will improve BWWB’s current plant operations. The upgrade was necessary to comply with the Safe Drinking Water Act by providing additional space for water storage to meet peak water demands. It also reportedly increases reliability of treatment, provides an optimal level of primary disinfection, improves the safety of the facility and makes certain that customers receive a continuous supply of high-quality water. (This story also can be found on Construction Equipment Guide’s Web site at www.constructionequipmentguide.com.) CEG
Photo courtesy of B.L. Harbert International LLC
Slab pour for the finish water pump station.
Photo courtesy of B.L. Harbert International LLC
Reinforcing for the walls for the transfer pump station.
Photo courtesy of B.L. Harbert International LLC
Interior of the finish water pump station.
Photo courtesy of B.L. Harbert International LLC
Interior of the transfer pump station.
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • December 12, 2012 • Page 7
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Page 8 • December 12, 2012 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide