Giorgio Foods Industrial WWTP Phase I Upgrade

Key Accomplishments

Johnston Construction Company

• Upgraded the existing influent pump station and incorporated new process pumping equipment and associated appurtenances.
• Constructed a new headworks facility supporting upgraded preliminary wastewater treatment operations.
• Installed a new Parkson Helisieve in-channel fine screening system designed for influent screening, solids transport, dewatering and discharge; the specified system was rated for approximately 840 GPM peak flow under normal two-pump operation.
• Constructed a new rectangular anaerobic treatment structure comprising two 20-foot by 20-foot basins, including mixers, hoists, guide systems, frames and related process equipment.
• Implemented major Biolac® biological treatment improvements using a long-sludge-age activated sludge process with biological nitrogen and phosphorus removal capability.
• Delivered treatment improvements designed around approximately 0.5 MGD average daily flow and 1.2 MGD peak flow, with alternating oxic and anoxic treatment zones for BOD removal, nitrification and denitrification.
• Installed and coordinated anaerobic mixers, aeration equipment, aeration blowers, RAS pumping, waste-sludge controls, post-aeration equipment and process instrumentation as part of the overall biological treatment system.
• Constructed and equipped a new 60-foot-diameter secondary clarifier, including spiral scraper mechanism, center influent column, rake arms, surface skimmer, feedwell, access bridge, platform, weirs, baffles and appurtenances.
• Upgraded the Return Activated Sludge / Waste Activated Sludge (RAS/WAS) pumping system, including new RAS pumping equipment and associated controls.
• Installed a new plant water system and new post-aeration system supporting the upgraded treatment process.
• Constructed a new approximately 1,700-square-foot operations building and renovated the existing blower building.
• Performed demolition of obsolete wastewater-treatment facilities, together with earthwork, yard piping, utility work, site improvements and associated appurtenances required for a complete operating facility.

Concrete Services Division

• Served as Subcontractor to Johnston Construction Company, the Prime Contractor, for concrete forming and placement work associated with the Giorgio Foods Industrial Wastewater Treatment Plant Phase I Upgrade.
• Furnished labor, materials, tools and supervision required for forming, concrete placement, finishing and curing in accordance with Division 1, Division 3, applicable addenda and the structural/process drawings.
• Performed concrete work for the new screen structure, including bottom slabs, thickened slab areas, south and perimeter walls, corners, divider wall, grout fillet, dumpster slab over the screen channel and dumpster pad.
• Constructed concrete foundations for the headworks canopy, including six column footings and six concrete columns.
• Completed extensive concrete work for the new operations building, including exterior and interior footings, stepped footings, exterior and interior foundation walls and floor slabs serving the electrical room, hall, toilet room, janitor room, laboratory and blower room.
• Formed and placed three blower equipment pads, the plant-water building floor slab and frost legs, and associated pump pads.
• Performed concrete construction at the influent pump station, including slabs adjacent to the wet well and the influent pump station valve-vault slab and walls.
• Constructed multiple reinforced-concrete pipe-support foundations for the air-header and aeration-tank piping systems.
• Completed concrete work for the RAS/WAS building, including the floor slab, frost legs and pump pads supporting wastewater-process equipment.
• Constructed additional process and equipment foundations including the existing belt-press pump pad, yard-hydrant bases, cleanout and valve pads, generator slab and frost legs, chemical-analyzer pump pad, make-up-air-unit pad and air-conditioning-unit pad.
• Formed and placed the lagoon effluent/clarifier splitter-box slab and walls as part of the plant's process-piping and treatment improvements.
• Performed installation and stripping of formwork, concrete placement and finishing, concrete curing, and associated finishing operations throughout the assigned structures.
• Installed project accessories associated with CSD's concrete scope, including vapor barrier, perimeter insulation, waterstop, premolded joint material, joint sealant and saw-cut joints, with designated materials furnished by JCC where specified.
• Provided required winter-protection labor and coordinated concrete placement activities to maintain productivity during seasonal conditions.