9 – The Commissioning Plan went into development at the 65% design stage in 2018 and, once completed, had nine volumes that detailed our approach to functional testing, programming verification, seeding and biological acclimation, sampling strategy, operational demonstration testing, and performance and acceptance testing. The volumes totaled over 2,160 pages of planning and test forms that laid the foundation for our successful turnover strategy.

10 – The number of process areas that were in various stages of testing at the same time. The PC closeout team divided up the plant – from the highly complex combined heat and power area to the extremely temperamental biological processes – and were able to execute testing safely and methodically to hit schedule milestones.

109 – The number of training sessions provided to the owner. At an average hourly session, this means that we trained for 27 weeks!

125 – There were 125 final Operation and Maintenance (O&M) manuals approved, updated, printed, and turned over to WSSC Water. To get to the final manual, each had to be submitted and approved for a preliminary and pre-final version. This resulted in 375 submissions just for O&M manuals! And that is on top of the 1,364 submittals the project team managed for a project this size.

2,740 – Hard input/output points were individually checked. And this doesn’t even get close to the soft IO points managed over ethernet for this project.

1,124 – The number of pages of programming process descriptions the team used to go line-by-line with the integrator to verify that all automation was functional, safe, and reliable.

1,314 – Assets entered into WSSC Water’s asset management program. As part of the closeout process, the team entered specific attributes ranging from size to horsepower and materials of construction that WSSC Water will use to identify, manage, and maintain the new infrastructure associated with this project.

34 – The longest continuous shift the commissioning team pulled to execute a series of tests. The team dedicated to the closeout of this project was amazing – they were committed to its success and were relentless in the pursuit of achieving performance and customer satisfaction.

306,782 – The number of samples and data points entered and analyzed during ramp-up and acclimation. From seeding through acceptance, a spreadsheet was maintained between WSSC Water and PC Construction to share sample results and real-time data so we could collaboratively make process decisions.

14 – There were 14 separate operational demonstration tests completed to prove the reliability of the facility, ranging from eight hours to continuous 30-day, 24/7 runs.

25 – There were 25 performance guarantee tests completed to prove the successful performance of the facility. These tests were designed to push systems and subsystems to their limits to ensure the system remains fully functional even in the most stringent conditions.

4 – The number of acceptance tests completed to achieve full acceptance of the facility.

The enormity of the commissioning process is so impressive to look back on. I am so proud and honored to have been a part of such a landmark project for WSSC. This project proved that with the right amount of collaboration and planning, anything is possible!

The post Final Completion Achieved for WSSC Bioenergy Project appeared first on PC Construction.

The NEWEA Conference is one of the premier events for water quality professionals in the Northeast, and provides an invaluable opportunity to explore the latest practices, technologies, and solutions shaping the industry. We look forward to collaborating with peers while sharing ideas and learning more about the future of the water and wastewater industry.

If you’re attending NEWEA this year, we’d love to connect! And if you aren’t able to meet up in Boston, feel free to reach out anytime to learn more about our work and our commitment to advancing water and wastewater treatment solutions.

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One of the most notable achievements involved a 900-cubic-yard concrete slab placement for a 15-million-gallon equalization tank. To maximize the efficiency, the first trucks rolled in at 2 a.m., eliminating site traffic congestion and optimizing pump truck access for the duration. Precon Corporation was crucial in the success of this operation and is now constructing the walls for two equalization tanks.

Adjacent to the equalization tanks, construction of the influent pump station included a 65-foot excavation through soil and rock, supported by a soil nail wall system. Using mass concrete, the structure was constructed and has been backfilled to grade. The team is currently completing masonry around the pump station’s electrical room, constructing the remaining elevated concrete slabs, and installing interior electrical and mechanical piping.

Significant upgrades are also in progress at the existing biosolids handling facility to incorporate a new thickening and dewatering polymer feed system. Once complete, these improvements will enhance reliability and efficiency in biosolids processing.

Additional construction activities include the installation of new yard piping, replacement of grit facility equipment, and the addition of chemical feed pumps at the Alkalinity Facility.

These efforts are all part of the broader expansion aimed at increasing the facility’s treatment capacity from 13.1 mgd to 16 mgd. Once completed, these Phase 1 improvements will help ensure Charlotte Water can meet growing demand while supporting ongoing development throughout the region.

The post Mallard Creek WRF Improvements Take Shape appeared first on PC Construction.

The project includes the replacement of the existing magnetic ion exchange (MIEX) treatment system with a fixed bed ion exchange (IX) treatment system to improve operation and provide consistent Total Organic Carbon removal for the largest provider of water, wastewater and reclaimed water in Osceola County. The IX process is a water purification method that exchanges mineral ions with contaminants in untreated water with ions that are less harmful for the end users. The system also relies on brine and salt storage tanks and an air wash system.

PC Construction will also add a pretreatment sand filtration system upstream of the new IX process and new odor control and stormwater management systems; replace the pump impellers on the existing well pumps; and complete modifications to the yard piping, site electrical, instrumentation and controls for the process equipment.

The groundbreaking marks the beginning of a phased, multiyear project that is on track to be completed in late 2027. PC Construction is excited to construct this project, which will increase water quality in the St. Cloud community and support TOHO’s infrastructure well into the future.

The post Construction Underway on Florida’s St. Cloud WTP appeared first on PC Construction.

The Cambi THP is a major component of the $270 million Bioenergy Facility and serves as a pre-treatment process upstream of anaerobic digestion, utilizing high temperature and pressure (375°F at 170 psi) to break down organic matter in the municipal wastewater sludge. This process enhances the biodegradability of the material, leading to increased biogas production and improved dewatering of the resulting Class A biosolids, all while reducing the volume of residual solids requiring offsite disposal. This particular facility is unique in that it is the first THP facility in the world to incorporate Cambi’s ‘redundant modules’, providing WSSC Water a full backup system in case a singular unit experiences failure.

The new Bioenergy Facility has been in operation for just over a year with operation and preventative maintenance tasks performed by WSSC Water. To ensure optimum performance and long-term reliability, Cambi requires the unit be taken out of service annually for maintenance, requiring a full shutdown. During that time, piping is taken apart and manways to the vessels are opened to properly clean and remove solids deposition. Pressure relief valves and the seats on the sludge and steam valves are also replaced.

Prior to the shutdown, the facility was processing over 65 dry tons of biosolids each day. Extensive coordination and pre-planning were required with WSSC Water operations staff located at the main Piscataway WRRF facility as well as the four other WSSC Water treatment plants that truck biosolids to the site. A shutdown and maintenance plan along with a detailed hour-by-hour schedule for the planned seven-day shutdown was developed, outlining individual work tasks and identifying which member of the integrated team was responsible for each task. PC Safety Specialist Mark Becker was also instrumental in working with Cambi and WSSC Water during this stage of the operation to address the work exposures of stored energy, high steam pressure and high temperatures. After multiple pre-planning sessions, the final plan review was held two days before shutdown initiation.

This was an intensive, collaborative effort involving all team members. The primary operation was led by Cambi with PC Construction providing administrative, safety and mechanical support and WSSC Water stepping in with operational oversight and additional mechanical support. In addition, Jet Blast provided high pressure washing and vacuum trucking services for the cleaning and flushing of the piping and vessels.

Special thank you to PC Construction’s awesome “Tear Down, Bolt-up, and Turn & Burn Team” whose expertise and talents contributed significantly to this successful outcome: Emanuel “Mocco” Negron, Alejandro “Yoyo” Vargas, Luis “Catracho” Rivera, Luis Rivas, Betzaida “Bee” Reyes and Gilberto “Shorty” Reyes. Cambi’s Dawn Taylor said it best: “I genuinely enjoyed working onsite with Mark, Mocco, and his crew. Their professionalism and teamwork truly stood out. Mocco and his team put in long, demanding days to accomplish a significant amount of work, all while maintaining a positive attitude and strong dedication.”

Following the safe and successful completion of maintenance, the THP was returned to service utilizing the redundant system one day ahead of schedule, a testament to the extensive planning and incredible team effort every member brought to the table. This milestone not only marks a successful first-year maintenance cycle but also reinforces the strength of collaboration, planning and technical excellence that has defined the entire Bioenergy Facility project.

A snapshot of the first two days of shutdown maintenance work, scheduled by the hour.

The post Collaborative Milestone Marks Successful Completion of Innovative Bioenergy Facility appeared first on PC Construction.

Being a part of such a communicative and collaborative team allowed me to be involved with the various project phases, from surveying to commissioning. Among the more complex tasks was using surveying equipment with my fellow engineers to grade and, in particular, field-measuring fiberglass ladders before fabrication. Additionally, I measured the elevations of welded beams before the erection of precast roof planks and also assisted with excavation layout. I learned to review shop drawings in several submittal packages and worked closely with manufacturers when coordination issues arose. For example, when I noticed a railing was restricting an oscillating HVAC damper, I field-measured the correct clearance and coordinated with the vendor.

Other project opportunities included performing quantity takeoffs for various materials ahead of communicating with vendors and suppliers for procurement. I completed a takeoff of stem extensions for submerged gate valves – using calculations based on the dimensions of each valve and the final grade elevation – and then corresponded these with the proper size of stem extension.

Another rewarding moment came when I worked with the senior commissioning manager to create a master equipment log. We reviewed all the piping and instrumentation diagrams and then recorded all key information, including spec, system, equipment, quantity, tag number and manufacturer. It was highly motivating to see my work have a positive impact on the project.

Additional highlights of my onsite experience included participating in weekly project look-ahead meetings, coordination meetings and office staff meetings. Together, these meetings allowed me to see everyone’s contributions come together and cultivate smooth and timely site operations. I was even able to hone my skills on key software platforms, including Bluebeam Revu and Procore, as essential technology tools to keep the project moving forward.

This comprehensive and enlightening experience has made me more confident, capable and motivated for my future in the construction industry. I am proud of the impact I made in such a short time, and I want to thank the PC project team for encouraging me to get involved and always taking the time to answer all my questions. I will miss my teammates, certainly. It’s easy to see how much PC puts people first, and I appreciated it immensely.

As I return to college this fall, I am committed to incorporating the PC values into my everyday life. At the end of the day, we are all BUILDING STRONGER, TOGETHER.

The post An Intern Experience: The Motts Run WTP Raw Water Pump Station Project appeared first on PC Construction.

Mayor Emma Mulvaney-Stanak was joined by Vermont Agency of Natural Resources Secretary Julie Moore, officials from the Vermont Department of Environmental Conservation, Department of Public Works Director Chapin Spencer, Water Resources Division Director Megan Moir, Lake Champlain Committee Executive Director Jenny Patterson, PC Construction President / CEO Matt Cooke and Water Resources staff to celebrate a ceremonial groundbreaking for this once-in-a-generation upgrade to the city’s wastewater facilities.

The project, which began initial construction activities earlier this month, is the beginning of a phased, multi-year upgrade and modernization effort. This phase will improve screening and grit removal infrastructure at all three facilities to help reduce downstream pollution, protect infrastructure and support future upgrades.

“Taken collectively, these projects will reduce overflow pollution to Lake Champlain, refurbish or replace old infrastructure, and secure wastewater treatment capacity — improvements which will support desperately-needed new housing and a thriving business community,” said Vermont Agency of Natural Resources Secretary Julie Moore.

Construction of this phase will wrap up late next summer.

The post Construction Underway for Vermont Wastewater Facility Upgrades appeared first on PC Construction.

The early phases made space for the new pump station work, which featured new structural steel framing and an elevated operating floor slab, installation of 24-inch and 48-inch suction pipe and discharge lines and four 800-horsepower vertical turbine high-lift pumps. All this work was successfully completed through more than 10 planned shutdowns, with each shutdown having a specific timeframe to maintain overall water production demands.

Many key planning measures were implemented to safely and successfully complete this work – all within or ahead of the available shutdown windows.

• There were multiple phases of work with immense precision requirements – notably the alignment and leveling between the previously cast-in-place concrete pads and piping with the pumps. An important quality control tool the crew utilized was an automatic laser level to help visually align the pumps with the numerous fittings that had extremely limited tolerances and flexibility.
• We developed custom large-format visuals mounted on wheeled carts to communicate our plans and processes. This was a very complicated scope and sequence of work, and we immediately saw the visual usage take off. We used them daily for our safety and Lean planning with our 20+ member process piping crew, but they also became a critical communication tool with plant operations, the design team, inspectors and other trades. These visual tools allowed the work to take place safely and with the high level of coordination needed.
• With no crane access in the building, our team was very creative with rigging and hoisting. We leaned heavily on dollies, chain falls and come-alongs to complete the work. Many times, while on a tight shutdown, rigging like this is strewn in gangboxes or even a five-gallon bucket. Before our work in the field started, the team built mobile tool and equipment carts for chain falls and come-alongs and another for wrenches and sockets. With this organized setup, we saw elevated production rates and the highest quality installation.

My piping crew and I are extremely proud of this work. This high-precision process mechanical and equipment work took many months to plan and was executed on schedule and without incident. The entire team was open-minded and willing to implement new ideas, which allowed us to overcome a very challenging scope of work with tight plant operational constraints to complete this major pump station upgrade successfully.

The post Precision Piping and Pump Installation Calls for Planning and Creativity appeared first on PC Construction.

Located on tight sites in highly populated areas inside city limits, the projects are challenging and require the implementation of both traditional and unique construction methods to get the job done safe, on time, on budget and to the highest degree of quality.

The new wastewater lift stations utilize sunken caisson wet wells as the primary structure and construction method. The cast-in-place concrete construction of the wet walls was completed above grade in sections, ranging from 16 to 18 feet in diameter, through multiple cylindrical concrete lifts. In addition, the wet wells are designed with a cutting profile cast into the concrete bottom. Two primary mechanics ensured the structures could sink in the Floridian soils with a high water table. First, the sheer weight of the structure enabled settling, with each section lift weighing upwards of 300,000 pounds. Second, excavating the soil within the interior of the structure initiated the cutting edge of the structure’s bottom, allowing the wet well to sink to its final location. Once the structure was sunk to its elevation, a plug slab was placed using an underwater tremie method, creating a watertight wet well structure.

In order to excavate the material from within the structure, the team used an innovative telescopic dipper arm, a teledipper. This specialized excavator attachment is designed for deep excavation applications and features a clamshell-style bucket mounted to a telescoping arm. The equipment has the ability to reach distances of 10 to 50 feet in depth at steep angles (including approaching 90 degrees), making it ideal for this type of work.

PC self-performed concrete construction along with site maintenance. We were fortunate to work with our trade partner, Danus Utilities, who expertly managed the specialty excavation via teledipper during this process.

This innovative sunken caisson method, and the use of the teledipper, reduced the area of impact by 80% when compared to conventional open-cut excavation and cast-in-place methods. The overall process also minimized hazards to existing utilities, public roads and pedestrian and vehicular traffic.

Photos Top to Bottom: 1) The teledipper excavating soil from within the interior of the structure; 2) Excavation at a near 90-degree angle; 3) The sunken wet well.

The post Challenging Projects Require Innovative Equipment appeared first on PC Construction.

PC Construction has been at the forefront of construction, design and project delivery in the water and wastewater market for over 60 years. From our first collaborative delivery project 45 years ago to the largest design-build water infrastructure projects of today, our teams and our work represent the largest East Coast water/wastewater geographical footprint in the market.

In our current portfolio, we are incorporating groundbreaking new technology at active plants in many communities. From biosolids transformations to advanced water treatment systems, PC is proud to lead high-performance design-build teams along the East Coast for:

• • • WSSC Water: Utilizing thermal hydrolysis process to transform regional biosolids management, generate biogas and reduce operating costs. Learn More
    • City of Bunnell, Florida: Providing clean drinking water using Reverse Osmosis technology.
    • Clayton County Water Authority: Increasing treatment capacity and incorporating advanced treatment processes for emerging contaminant removal.
    • Charlotte Water: Efficient biosolids treatment incorporating thermal hydrolysis process.
    • Arlington County, Virginia: Reducing greenhouse gas emissions and advancing sustainability goals using thermal hydrolysis process. Learn More
    • City of New Smyrna Beach, Florida: Incorporating cutting edge water softening and purification technologies.
    • City of Atlanta, Georgia: Providing critical pumping system improvements to secure Atlanta’s water supply for the next 100 years. Learn More

Want to learn more? A team of PC design-build leaders from across our regions are eager to connect with our industry partners at the DBIA Water/Wastewater Conference. Stop by booth #517 to say hello, check out our new look, and enjoy a mouthwatering giveaway!

The post Join PC Construction at the DBIA Water/Wastewater Conference appeared first on PC Construction.

We brought the group into the office trailer and conducted a Lean crash course to illustrate how the field team schedules upcoming work, inspections, and subcontractor collaboration using Nialli software and interactive smart boards. This provided a practical, hands-on application illustrating workflow navigation and effective field project management.

The students who attended the tour had great questions and positive feedback from the project visit, highlighting the importance of practical learning outside of the classroom and networking for their future construction career.

The post Western Carolina University Students Tour Site, Learn Lean Techniques appeared first on PC Construction.

The MRRC, located on a half-acre site in Middlebury, is a cutting-edge facility designed to convert food and beverage waste into renewable biogas. Through PurposeEnergy’s innovative Tribrid-Bioreactor system, the center processes approximately 80,000 gallons of organic waste daily, producing 1.014 MW of electricity for Vermont homes and businesses on a 24/7 basis. This environmentally focused project reduces greenhouse gas emissions by over 2,000 tons of CO2 each year, equivalent to eliminating 278 tanker truck trips each month.

The project’s commitment to sustainability extends beyond energy generation. The MRRC also plays a vital role in phosphorus sequestration, preventing over 60 tons of phosphorus from entering Otter Creek and Lake Champlain annually. Furthermore, the facility’s infrastructure supports local food and beverage manufacturers, such as Agri-Mark for Cabot Creamery and Vermont Cider Company, by offering an environmentally friendly and cost-effective solution for waste disposal.

The project faced numerous challenges but by embracing a collaborative, transparent approach, we delivered a successful project with zero safety incidents.

Winning the AGC Vermont Best Builders Award is a proud moment for our team, and we look forward to the continued positive impact the MRRC will have on Vermont’s communities.

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