Fort Smallwood 2.0 MG Composite Elevated Water Storage Tank

Key Accomplishments

Johnston Construction Company

• Installed 72 auger-cast-in-place piles, including the required pile testing, to support the composite elevated tank foundation. JCC's subcontract expressly assigns the 72 piles and testing to Johnston.
• The pile specification required a minimum allowable compression capacity of 160 tons per pile, with final foundation requirements coordinated with the tank manufacturer's loading.
• Constructed the tank foundation designed by Caldwell, including the specified 6-inch concrete floor, and completed grading and clean-stone placement within and around the ringwall to prepare the site for Caldwell's tank erection operations.
• Furnished and installed the assigned water piping and mechanical systems, including valves, manholes, fittings and appurtenances serving the tank's inlet, outlet and overflow piping up to the 20-inch ductile-iron-pipe/steel adapters.
• Constructed the associated valve vault and supporting civil/mechanical improvements required for operation of the tank piping system.
• Performed pressure/leakage testing, sterilization and water-quality acceptance activities for JCC-installed piping and submitted supporting test documentation. The project specifications required pressure water piping to be hydrostatically tested before service and potable-water piping to be cleaned, chlorinated, flushed and bacteriologically accepted.
• Furnished insulation and heat tracing for the 1/2-inch copper sensing line extending from the tank floor to the connection through the tank tube. The overall heat-tracing specification required a complete self-regulating electric heat-trace system with thermostatic controls and associated accessories.
• Provided and installed the electrical and instrumentation work assigned to JCC on the project drawings. The project electrical scope included secondary electrical service, grounding and bonding, raceways, wire and cable, panelboards, lighting, field instrumentation, controls and associated testing.
• Coordinated electrical and instrumentation interfaces associated with the elevated tank's control systems, including field devices and the infrastructure supporting the PLC, telemetry and process-control systems, while maintaining the contractual separation between JCC's installation obligations and specialized control-system integration/programming.
• The instrumentation design incorporated potable-water monitoring for pH, conductivity, free chlorine and turbidity, together with associated transmitters, sensors and monitoring equipment.
• Completed miscellaneous closeout construction associated with the tank base, including the masonry room, roofing, hatches, doors, insulation/painting, grouting, overhead and personnel doors, exterior concrete sidewalks and entrance slabs, pipe bollards, piping supports, under-slab drains and miscellaneous copper work, as required by JCC's subcontract.
• Completed extensive site-finishing work including paving, sidewalks, fencing, a 20-foot by 6-foot stone apron around the tank shaft, infiltration trench/riprap, splash pad, final grading, seeding and the final access drive.

Concrete Services Division

• Concrete Services Division, LLC served as the Concrete Subcontractor to Johnston Construction Company for the Fort Smallwood Elevated Water Storage Tank project in Pasadena, Maryland.
• Furnished the labor, forming materials, tools and equipment required for the forming, placement, finishing and curing of approximately 366 cubic yards of structural concrete associated with the elevated water storage tank foundation and related improvements.
• Performed approximately 1,969 square feet of curved-wall forming and placed approximately 310 cubic yards of wall concrete, forming a major portion of the structural concrete work included in CSD's subcontract.
• Formed and placed approximately 56 cubic yards of slab-on-grade concrete, together with the associated concrete finishing and curing operations.
• Performed concrete work associated with the interior tank floor slab and pile-cap construction, supporting the foundation system for the new elevated water storage tank.
• Completed concrete construction associated with the project's splash pad, base-elbow supports, pipe supports and equipment/support pedestals, integrating the concrete work with the surrounding mechanical piping and tank-foundation systems.
• The subcontract included approximately 96 square feet of slab-on-grade forming and substantial curved-wall formwork requiring close control of dimensions, alignment and concrete placement.
• Performed approximately 1,818 square feet of float/screed finishing and approximately 2,463 square feet of machine-trowel finishing across applicable slab and structural concrete surfaces.
• Completed approximately 1,969 square feet of point-and-patch finishing, along with additional bag finishing required to produce completed concrete surfaces.
• Provided labor and materials associated with concrete curing across approximately 6,346 square feet of concrete surface. Section 03300 required freshly placed concrete to be protected from premature drying and temperature extremes, with applicable unformed surfaces maintained under specified curing procedures for not less than seven days.
• Installed and stripped formwork in accordance with the project's cast-in-place concrete requirements. Supporting formwork was required to remain in place until the concrete achieved at least 70 percent of its 28-day design compressive strength.
• Coordinated concrete construction around the project's reinforcing system. Section 03300 specified ASTM A615 Grade 60 deformed reinforcing bars and Grade 60 joint dowels for the cast-in-place concrete work.
• CSD's billing schedule incorporated approximately 24.25 tons of reinforcing-steel work and 36 dowels, coordinated with reinforcing materials and related support furnished or managed by Johnston Construction Company in accordance with the subcontract.
• Furnished form lumber and form materials; installed and stripped forms; provided concrete-placement labor; performed finishing, curing, joint/accessory work and associated labor required for the CSD concrete scope.

Electrical Services Division

• Electrical Services Division, LLC performed the electrical trade work under Johnston Construction Company for the Fort Smallwood Elevated Water Storage Tank.
• Furnished all labor, materials and tools required to complete the assigned electrical work in accordance with the contract plans, specifications and Electrical Drawings E-1 through E-7.
• Furnished and installed power conduit, conductors, wiring and electrical connections serving equipment throughout ESD's assigned scope.
• Furnished and installed instrumentation conduit, control wiring and associated electrical connections required to support the tank monitoring and control systems. Instrumentation equipment itself was furnished by others.
• Installed and wired the cathodic protection panel serving the elevated water storage tank.
• Constructed approximately 160 linear feet of underground electrical ductbank from the new tank to the project handhole, including trenching, concrete encasement where required and backfill.
• Furnished and installed the assigned switchgear, panelboard components, boxes, devices and associated electrical distribution equipment. The subcontract separately identified lighting, conduit, boxes/devices, wire and switchgear as major portions of ESD's work.
• Furnished and installed the Panelboard LP-A transient-voltage surge suppressor required by the project.
• Furnished and installed electrical work supporting the complete tank lighting system, including fixtures, conduit, wiring, switching and controls.
• Supported interior tank lighting, altitude valve room lighting, ladder and platform illumination, exterior access lighting, emergency lighting and exit lighting in accordance with the project requirements.
• Coordinated electrical work associated with the project's FAA obstruction-lighting system serving the elevated tank.
• Furnished and installed assigned grounding and bonding components, including grounding conductors and equipment grounding connections.
• Installed the ground rods and grounding cable associated with the lightning-protection interface shown on Electrical Drawings E-2 and E-3. The complete lightning-protection system was excluded from ESD's subcontract and furnished by others.
• Performed electrical installation associated with the pipeline heat-tracing system, supporting freeze protection for designated piping.