Franklin-Malone 0.75 MG Water Storage Tank & Rechloramination Station

Key Accomplishments

Johnston Construction Company

• Installed the major water-main and process-piping infrastructure serving the new storage facility. JCC’s subcontract included piping, valves, fittings, hydrants, supports, and thrust blocks from the limits of the existing 16-inch waterline at South Hewitt Avenue to the new tank connections. Contract pricing also incorporated approximately 250 LF of 12-inch water main, 20 LF of 8-inch water main, and one 12-inch magnetic flow meter.
• Constructed the foundation and under-slab piping for the prefabricated rechloramination station and coordinated installation of the Owner-furnished treatment station. JCC’s contractual package also incorporated chemical-injection lines, water-analyzer lines, ductile-iron piping taps, drainage, and the civil and mechanical interfaces necessary to integrate the rechloramination system with the new storage facility.
• Completed the principal site drainage and access improvements, including drain lines and drain manholes, approximately 150 LF of SDR-35 PVC drain line, 150 LF of HDPE drain line, approximately 12,500 SF of driveway and site pavement, and approximately 430 LF of fencing and gate work, together with bollards, access-road subbase, bituminous paving, and associated site restoration.
• Provided quality-control support for foundation and site construction, including concrete testing, soils testing, and subgrade-bearing inspections with the required reports, helping verify foundation and subgrade conditions before and during permanent construction.
• Coordinated the civil construction with tank erection, treatment equipment, electrical, instrumentation, SCADA, and other project trades, allowing underground utilities, conduits, piping, foundations, and site improvements to be installed at the proper stages of the overall tank-construction sequence.
• Completed final site restoration and project closeout, including grading, seeding, removal or completion of temporary site controls, and maintenance of required record drawings, warranties, and operation-and-maintenance documentation associated with JCC’s subcontract work.
• Johnston Construction Company served as the Civil Subcontractor for the Franklin-Malone Water Storage Tank and Rechloramination Station project in Washington County, Pennsylvania. The project was constructed for Pennsylvania-American Water Company, with CB&I LLC serving as the Prime Contractor. Pennsylvania-American Water Company’s contract documents identify Rachael Beam as Engineer for the Franklin-Malone Tank, while the project drawings were prepared by Gwin, Dobson & Foreman, Inc.
• The overall project provided a new 0.75-million-gallon welded steel water storage tank on Pennsylvania-American Water Company property along South Hewitt Avenue in Canton Township. The complete facility included tank and foundation construction, excavation and grading, erosion and sediment controls, yard piping, stormwater-management improvements, water-main work, the rechloramination station, electrical and instrumentation systems, fencing, paving, and site restoration.
• JCC’s civil work began with site layout, erosion and sediment controls, clearing, grading, and preparation of the tank site. The subcontract included construction of the spread-footing tank foundation, installation of required foundation conduits, construction of the 6-inch concrete floor slab, interior concrete floor and pipe supports, and preparation of the site for subsequent tank erection. JCC also provided concrete testing, soils testing, and subgrade-bearing inspection associated with the work.
• A substantial portion of JCC’s scope involved the permanent water and drainage infrastructure. JCC’s subcontract included piping, valves, fittings, hydrants, supports, and thrust blocks between the South Hewitt Avenue water-main limits and the new tank. The contractual pricing incorporated approximately 250 linear feet of 12-inch water main, 20 linear feet of 8-inch water main, a 12-inch magnetic flow meter, SDR drainage piping, HDPE drainage piping, and associated appurtenances.
• JCC also completed the civil and mechanical work associated with the rechloramination station, including its foundation and under-slab piping and installation coordination for the prefabricated station furnished by Pennsylvania-American Water Company. Chemical-injection lines, water-analyzer lines, piping taps, drainage, and associated utility connections were incorporated into the work so the rechloramination system could function as part of the completed water-storage facility.
• Final site construction included fencing and gates, bollards, access-road subbase, bituminous paving, drainage improvements, grading, restoration, and seeding. JCC also maintained the required record drawings, warranties, and operation-and-maintenance documentation for its work through project closeout.

Concrete Services Division

• Performed the specialized cast-in-place concrete package supporting Pennsylvania-American Water Company’s new 0.75-million-gallon Franklin-Malone water storage facility. CSD’s work supported the tank foundation, the new rechloramination building and associated concrete structures within a larger project that included the water-storage tank, water mains, treatment equipment, drainage, electrical, instrumentation and SCADA systems.
• Provided the labor, materials, tools and concrete-trade services required for the tank foundation, rechloramination building footings and walls, building slab, tank slab, generator slab and associated concrete work. The subcontract specifically incorporated forming, concrete placement, finishing and curing operations for these structures.
• Placed approximately 210 cubic yards of structural concrete across the contracted tank and building components. The detailed control estimate included approximately 114.38 CY of tank footing concrete, 40.62 CY of tank wall concrete, 11 CY of tank slab-on-grade, 27.23 CY of building wall concrete and 16.65 CY of building slab-on-grade concrete.
• Constructed extensive formwork for both the tank foundation and rechloramination building, including approximately 167 SF of tank-footing forms, 1,097 SF of curved tank-wall forms, 490 SF of straight building-wall forms and 112 SF of building slab-on-grade forming.
• Completed multiple concrete-finishing operations tailored to the different structural surfaces, including float-and-screed finishing, machine troweling, point-and-patch work and bag finishing for both the tank and building concrete. The contracted quantities included more than 1,800 SF of float-and-screed work on tank concrete and substantial wall patching and surface finishing.
• Performed reinforcing-steel installation support and anchor-bolt setting as part of the concrete package. CSD’s responsibilities included reinforcing-steel placing labor, unloading and handling reinforcement with JCC-provided equipment and setting anchor bolts so reinforcing and embedded components could be properly integrated before concrete placement.
• Installed and coordinated concrete accessories required at structural joints and penetrations, including labor associated with premolded joint materials, waterstop, caulking and related accessories. CSD coordinated these items with JCC before and during concrete placement to maintain the required joint and structural details.
• Constructed four concrete pipe pads associated with the facility piping systems, integrating the supports with the broader civil and mechanical infrastructure serving the new water-storage and rechloramination facilities.
• Coordinated concrete supply, pumping and testing with Johnston Construction Company. JCC furnished or paid for the concrete material, concrete-pump rental and concrete-testing services, while CSD coordinated those activities and supplied the labor necessary to place, finish and cure the concrete.
• Performed winter-concrete labor and protection coordination where required, while JCC supplied the winter-protection blankets and heaters. The work required coordination of protection measures with placement and curing activities so completed concrete could be protected during cold-weather conditions.
• The tank portion of CSD’s work included footing, curved-wall and slab concrete. The control estimate identifies approximately 114.38 cubic yards of tank-footing placement, 40.62 cubic yards of tank-wall placement and 11 cubic yards of tank slab-on-grade placement. Formwork included approximately 167 square feet at the footing and approximately 1,097 square feet of curved tank-wall forming.
• Concrete construction for the rechloramination building included building walls and slab-on-grade work. CSD placed approximately 27.23 cubic yards of wall concrete and 16.65 cubic yards of slab-on-grade concrete, together with approximately 490 square feet of straight-wall forming and approximately 112 square feet of slab-on-grade forming.
• CSD’s responsibilities extended beyond placement and forming. The subcontract included reinforcing-steel placing labor, reinforcement handling, anchor-bolt setting, concrete accessories, waterstop and joint-related labor. Concrete finishing incorporated float-and-screed work, machine-troweled surfaces, point-and-patch repairs and bag finishing. Curing labor and supplies were also included within the concrete package.
• Concrete material itself, pumping rental and testing services were provided or paid for by Johnston Construction Company, but CSD coordinated each of those activities with its own concrete operations. CSD also coordinated winter protection, with blankets and heaters furnished by JCC while CSD supplied the associated field labor and placement coordination.

Electrical Services Division

• Performed the electrical construction package supporting Pennsylvania-American Water Company’s new 0.75-million-gallon Franklin-Malone Water Storage Tank and associated site facilities. ESD’s subcontract covered electrical systems required for the tank, site infrastructure and related equipment in accordance with the project’s Division 16 specifications and electrical drawings E-1 through E-10.
• Furnished and installed the project’s principal power-distribution infrastructure, including power conduit, conductors, wiring and electrical connections together with the electrical service, panelboard, surge-protection device and switchgear required for the completed facility.
• Installed instrumentation conduit, wiring and electrical connections serving the tank instrumentation and control systems. This work provided the field electrical infrastructure necessary to interface process instrumentation with the overall control and telemetry system serving the completed storage facility.
• Completed the tank and site lighting systems, including fixtures, switches, receptacles, wiring devices and associated raceway and branch-circuit work. The subcontract specifically incorporated the project’s building-lighting and occupancy-sensor specification sections.
• Wired the packaged emergency-generator system furnished by Johnston Construction Company, providing the electrical connections required to integrate standby power into the completed tank facility. ESD’s contract specifically assigned generator-system wiring to ESD while the generator equipment itself was furnished by JCC.
• Installed electrical systems associated with motor control, disconnects, grounding and equipment power, working under specifications covering grounding, safety switches and disconnects, motor control, transformers, panelboards and general electrical provisions.
• Performed instrumentation and control-related coordination for the new water-storage facility, which incorporated tank instrumentation, chemical and water-analysis systems, the Owner-furnished telemetry RTU and other process-monitoring equipment. ESD coordinated its conduit and wiring installation with equipment and materials supplied by other project participants.
• Performed heat-trace electrical work included within ESD’s schedule of values, coordinating the installation with the piping and treatment-system improvements incorporated into the Franklin-Malone project. The broader construction scope included heat tracing associated with chemical-injection and water-sample lines.
• Completed underground electrical construction and raceway work while coordinating civil interfaces with JCC. ESD’s scope included the electrical conduit systems, while trenching, concrete encasement where required and backfill for underground ductbanks were expressly assigned to others.
• Provided electrical permitting, inspection, testing and startup support, including coordination of testing services and one day of startup assistance. ESD also prepared the required submittals, O&M documentation and as-built/record drawings for its completed electrical work.
• The Franklin-Malone contract documents were prepared by Gwin, Dobson & Foreman, Inc., with CB&I LLC serving as the Prime Contractor and Johnston Construction Company performing the major civil package. ESD worked under Johnston Construction Company as the project’s electrical trade subcontractor.
• ESD’s work included the complete installation of major electrical raceway and wiring systems required by the project electrical drawings. The subcontract specifically incorporated specifications for electrical general provisions, conduit, wires and cables, boxes, wiring devices, panelboards, grounding, safety switches and disconnects, underground electrical construction, transformers, lighting, motor control, packaged engine-generator systems and electrical testing and startup.
• The completed project also incorporated an emergency standby generator. The generator equipment was furnished through Johnston Construction Company, while ESD was specifically responsible for wiring the packaged engine-generator system and making the electrical connections associated with its installation.
• Project closeout included coordination of inspection and testing services, startup assistance, review and submission of required documentation, O&M manuals and preparation of as-built/record drawings reflecting the completed electrical installation.