Defense Distribution Center Susquehanna – New Cumberland WWTP Replacement

Key Accomplishments

Johnston Construction Company

• Demolished major existing treatment facilities, including the influent screening system, Oxigest unit, tertiary filters, chlorine contact tank, Filter Building, Chlorine Building, Control Building and Alum Storage Building.
• Constructed a new Screening Building and influent screening system, Distribution Chamber, flow-meter vault and associated process infrastructure.
• Constructed two new Sequencing Batch Reactors (SBRs) and a new aerated sludge holding tank as major components of the replacement biological-treatment process.
• Installed a new ultraviolet disinfection system, UV channel and post-aeration tank to provide upgraded final treatment and disinfection.
• Constructed a new Chemical and Blower Building incorporating new process blowers, chemical storage and chemical-feed facilities.
• Constructed a new Control Building incorporating laboratory and office spaces for plant operations.
• Installed a new Plant Water Vault and non-potable plant-water pumping system, together with process pumps, piping, valves and associated mechanical equipment.
• The replacement treatment facilities were designed for approximately 0.320 MGD maximum-month-average flow and to support applicable nutrient-reduction and wastewater-discharge requirements.
• Furnished and coordinated a comprehensive Process Instrumentation and Control System (PICS) incorporating PLC-based control panels, HMI operator stations, operator-interface terminals, alarm monitoring, trending and process-equipment supervision.
• Integrated process facilities through an Ethernet-based fiber-optic communications network, providing connectivity between plant buildings, process control panels, operator stations and vendor-supplied control systems.
• Installed and coordinated control panels, field wiring, fiber-optic communications, instrumentation interfaces, raceways and equipment interconnections required for the integrated plant-control system.
• Constructed new electrical infrastructure including electric service, power distribution, lighting, instrumentation and controls, and emergency generator systems.

Concrete Services Division

• Concrete Services Division, LLC served as the concrete subcontractor to Johnston Construction Company for the New Cumberland Wastewater Treatment Plant replacement at the Defense Distribution Center Susquehanna.
• CSD's subcontract encompassed major structural and site-concrete work associated with the replacement wastewater treatment facilities, with the original subcontract pricing schedule totaling approximately 1,291 cubic yards of concrete-related work.
• Performed concrete forming, placement, finishing and curing for major wastewater-treatment structures including the Control Building, Screening Building, Chemical and Blower Building, Sequencing Batch Reactors, UV Channel, Post-Aeration Tank, Plant Water Vault, Equalization Pump Station pipe supports and Distribution Chamber.
• Provided forming operations including footing forms, slab-on-grade forms, straight-wall forms, column forms, suspended-slab forms, bulkheads and special forming required for the plant structures.
• Installed and stripped concrete formwork and performed concrete placement labor for footings, slabs-on-grade, walls, columns and suspended slabs throughout the treatment-plant construction.
• Completed reinforcing-steel placement associated with the structural-concrete scope, together with reinforcing mesh and dowels identified in the subcontract pricing schedule.
• Installed concrete accessories including vapor barrier, perimeter insulation, waterstops, premolded joint material, sealants and joint materials as required for the concrete work.
• Performed concrete finishing operations, including float/screed finishing, machine troweling, point-and-patch work, bag finishing and concrete curing.
• Completed substantial concrete work associated with the new SBR treatment structures, which formed the core biological-treatment process of the replacement wastewater treatment plant.
• Performed concrete construction for the UV disinfection channel and post-aeration facilities, supporting the plant's upgraded downstream treatment and disinfection systems.
• Constructed concrete associated with the new Plant Water Vault and additional process structures required for plant-water and process-mechanical systems.
• Installed concrete pipe supports and pipe pads serving the extensive wastewater process-piping systems throughout the facility.
• Completed concrete foundations and pads associated with equipment, mechanical systems and process infrastructure throughout the project.
• Performed site and yard concrete including entrance-gate operator pads, entrance concrete paving, concrete steps, transformer pad, generator pad, Screening Building approach pad, dumpster pad, Chemical/Blower Building equipment pad and Sludge Loading Station concrete.

B & R Electrical Contractors

• B & R Electrical Contractors, Inc. performed the major electrical construction package associated with Johnston Construction Company’s replacement of the New Cumberland wastewater treatment plant at the Defense Distribution Center Susquehanna.
• Furnished the labor, materials, tools and electrical installation required for the new wastewater-treatment facilities under a federal U.S. Army Corps of Engineers project.
• Installed extensive conduit, power conductors, control wiring and electrical connections serving treatment-process equipment, buildings and supporting infrastructure.
• Furnished and installed switches, receptacles, panelboards, disconnect switches and electrical distribution equipment throughout the replacement facility.
• Installed a 500 kVA pad-mounted transformer, together with associated medium- and low-voltage distribution components identified in the electrical subcontract.
• Installed motor-control and power-distribution equipment, including the MCC serving the Chemical and Blower Building and related plant systems.
• Installed the plant's automatic transfer switch infrastructure and associated emergency-power distribution connections.
• Performed electrical construction associated with major wastewater process facilities including the Control Building, Chemical and Blower Building, Influent Screening Building, Plant Water Vault, Sequencing Batch Reactor Valve Vault, Distribution Chamber and other process structures.
• Provided extensive temporary electrical power infrastructure necessary to keep the existing treatment plant operational while new facilities were constructed and commissioned.
• The temporary-power work included multiple phased temporary electrical taps and distribution installations as construction progressed through the active facility.
• Furnished and installed poles for temporary electrical service, supporting the phased plant-replacement sequence.
• Installed complete interior and exterior lighting systems, including wiring and associated electrical distribution.
• Installed the specified lightning-protection system for the new treatment-plant facilities.
• Installed electrical wiring supporting intrusion detection, electronic security, CCTV and fire-alarm systems, with the specialty systems/components furnished separately where identified by the subcontract.