American Gulch Water Reclamation Facility Expansion

 November 5, 2014

The expansion of the District’s water reclamation Facility has been underway for over a year. After several months, the project team has completed value engineering and final design for the last phase of the process upgrades and system improvements.  Major components and systems were bid to various suppliers and vendors based on a detailed set of performance specifications and plans. The team held various interviews and site visits in order to achieve selections which would best meet the District’s needs and provide the best options currently available, at the best value and cost.  At a Special Board Meeting held on, September 25, 2014, the Board of Director’s received and reviewed the Guaranteed Maximum Price (GMP) #4 proposal presented by Moore and Associates, Currier Construction Inc., and District staff.

The majority of the work will include construction, retrofitting, replacement, and startup of new tertiary final filters, ultraviolet disinfection systems, and modifications to convert a previous Volatile Fatty Acid production basin into a 4th secondary sedimentation basin.  Not only will the new treatment trains be able to handle higher flows, but the equipment chosen was specifically selected to comply with current advancements in wastewater treatment technology, increase energy efficiency and meet compliance requirements for effluent discharge, groundwater protection, and reuse permits.  An Aquifer Protection Permit Major Modification Amendment was required to be filed with the Arizona Department of Environmental Quality for the District’s facility.  The amendment is currently under the Department’s review and final approval is anticipated prior to startup and operation of the expansion project.

On September 25, 2014, the Board unanimously approved GMP #4 in the amount of $2,559,300.41.  The addition of GMP #4 brings the current project commitment for facility upgrades under the CM@R contract to $11,284,253.11.  This work is to be performed concurrently with previous GMPs and is scheduled for a July 2015 completion.  Once the construction is completed, the District will undertake major reconstruction and repair of the landscaping and pavement around the facility.

 Overall Project Totals

$360,000.00 – Engineering and Design Services

$10,000.00 – ADEQ Permit Amendments

$399,396.00 – Construction Scoping Services

$11,284,253.00 – Construction Management at Risk Contracts GMPs #1 thru #4

$250,000.00 – Miscellaneous District Project Expense (estimated)

$12,303,649.00  –  Total              

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May 2, 2014

 After many long months of working through the equipment, electrical controls, and process instrumentation aspects of the Bardenpho and Volatile Fatty Acids basin design, the Board of Directors have approved the next phase of the CM@R contract with Currier Construction.  After value engineering, competitive vendor pricing, and finalizing selection of all the components to complete the system improvements for this phase of the work, the Guaranteed Maximum Price was approved for $5,233,262.00.

The District has elected to use energy conserving turbine blowers to supply oxygen to the biological process.  With the installation of a new control solution and modification to the ceramic stone diffuser aeration system, it is anticipated the District will save considerable power over the current methods. Four (4) major underground piping bores operations will be necessary to connect all of the process basins into the existing secondary sedimentation basins.  Both the additional capacity and the process advancements in the process were a mandated requirement within the Districts Federal and State discharge permits.  The design engineer, Moore and Associates has submitted a Major Modification Application for the Districts Aquifer Protection Permit to seek final approval of the improvements from the Arizona Department of Environmental Quality.  This work is expected to continued throughout 2014 and be completed in late spring of 2015.

Engineering will now continue and focus on the remainder of the plant process.  This will include replacement of the tertiary filtration units and final disinfection processes.  Aside from increased capacity, the units will be designed to utilize new advancements in technology and energy conservation.  Funding for this entire expansion and modification project has come from many years of conservative spending and saving reserve funds.  There has been no borrowing, bond sales, or any increase in service fees or other rates, to fund this work.

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August 22, 2013

On August 8, 2013, the Board approved the next step in the overall planned expansion to construct a Volatile Fatty Acids Basin. This new basin will replace the current VFA basin which was built in 1989. The new design will incorporate changes as a result of lessons learned from past and present day operations, as well as to insure ample capacity for the future growth of our community in the coming years. The purpose of this part of the treatment plant process is to biologically produce volatile fatty acids utilizing the natural organisms entering the facility. As the production of hydrogen sulfide begins to form in this basin, volatile fatty acids will be produced in the liquid. As this flow enters the biological treatment trains, known as the Bardenpho Process, the VFAs produced will aid in enhancing the removal of phosphorus from the effluent water. The District is faced with very strict discharge limits for both phosphorus and nitrogen in their Federal and State permits.

The design engineer and the District’s CM@R contractor have prepared the plans for the concrete structure. Currier Construction presented GMP#2 for review and approval in the amount of $1,290,174 for this phase of the project. Major components of this work will include a massive shoring system being put into place prior to the excavation of the area for the VFA basin, demolition of existing concrete structures, forming, pouring and finishing of a 70,000 cubic foot concrete structure, backfilling and potential groundwater remediation. The work is planned to occur simultaneously with the construction of the new Bardenpho basin and will extend the timeline an additional 3 months. The next portion of work will center around installing all the necessary components to make the new structures operational.

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July 16, 2013

At their regular Board Meeting on July 11, 2013, the Board approved the first phase, of a multi- part project, to increase the capacity of the biological treatment components of the wastewater treatment facility from 2,200,000 to 3,500,000 gallons per day. Currier Construction from Phoenix, Arizona has been selected as the Construction Manager at Risk contractor for the project. The District has had previous experience with Currier Construction and its owners on other successful District projects. The design work has been completed under contract with Moore and Associates, with Currier Construction assisting with value engineering and cost evaluation.

This first portion of work will include excavation, dewatering, and construction of a third Bardenpho process basin alongside the existing two. This work will include removal/disposal of unsuitable soil from the excavation site. A dewatering system of wells and pumps has been built to deal with expected nuisance groundwater within the work areas. Once the concrete structures of the basin are formed, poured and completed, backfill material will be transported back into the site and compacted to finalize this portion of the additions. This structure is approximately 180,000 cubic feet in size. Currier Construction has provided a maximum guaranteed price for this work at $2,093,698. Work is expected to be completed on this portion within 6 months and continue into the next portion of work, located upstream of the Bardenpho process, which will be the construction of a new Volatile Fatty Acids Basin.

Watch a Video of Construction Progress

Progress

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