Giorgio Foods WWTP Phase 1 – Lagoon Aeration System Improvements

Key Accomplishments

• Sequenced installation of the new diffuser system in stages so portions of the replacement aeration system could be installed and tested while the existing treatment process remained operational.
• Furnished and installed new above-ground process air piping, concrete foundations, structural supports, handrail improvements, and associated miscellaneous metals.
• Removed existing underwater aeration equipment and existing perimeter safety railing as part of the lagoon renovation.
• Coordinated installation of supplemental lagoon aeration equipment incorporating a Clean-Flo stainless-steel manifold and micro-porous ceramic diffuser system designed to increase dissolved oxygen within the wastewater lagoon.
• Performed cleaning, pressure testing, and leak verification of the new process air-header system.
• Completed the work within an active industrial wastewater treatment environment requiring careful sequencing, equipment coordination, and protection of ongoing plant operations.
• Johnston Construction Company served as the Prime Contractor for improvements to the existing industrial wastewater treatment system at Giorgio Foods, Inc. The project focused primarily on renovation and expansion of the wastewater lagoon's aeration system, along with the associated process piping, structural, concrete, railing, demolition, and support work.
• A major component of the project was installation of a Parkson Biolac® W treatment system serving the existing aeration basin. The project-specific Parkson submittal identifies the equipment as a Biolac W system under Project No. P05000868. The system incorporated BioFlex moving aeration chains, BioFuser fine-bubble diffusers, HDPE air piping, electrically operated butterfly valves, stainless-steel chains and cables, counterweights, and associated aeration components.
• The Parkson equipment schedule included 151 manifold assemblies, 227 BioFuser 3000 diffusers, 15 four-inch electrically operated butterfly valves, HDPE piping, hoses, stainless-steel hardware, wire rope, chains, and related aeration-system components.
• Installation of the replacement aeration system required careful sequencing because Giorgio Foods' wastewater treatment process needed to remain operational throughout the renovation. The new diffuser assemblies and air-distribution components were installed and tested in stages, allowing the existing aeration equipment to continue functioning until the replacement system was ready for service.
• JCC also installed the associated process air-header piping system, including piping, fittings, valves, insulation, supports, anchors, and accessories. The project specifications required the completed air piping to be cleaned and pressure tested, including a leakage test at 12 psig for one hour.
• Supporting construction included cast-in-place concrete foundations and miscellaneous concrete work. Project specifications required reinforced concrete construction using 4,000-psi concrete, together with formwork, reinforcing steel, placement, finishing, curing, and field quality-control testing.