LocationDowningtown, Chester County, Pennsylvania
MarketWater Supply and Infrastructure
Contract
$2,041,454
Team Members
- Owner
- Commonwealth of Pennsylvania – Department of Conservation and Natural Resources
- Engineer
- Pennsylvania DCNR – Bureau of Facility Design and Construction
- Prime Contractor
- Concrete Services Division, LLC
Key Accomplishments
- Obtained concrete core samples from the existing spillway weir and walls and performed petrographic analysis to evaluate concrete condition and determine the depth of deterioration before repair operations.
- Performed controlled demolition of the deteriorated upper portion of the existing ogee spillway and removal of damaged wall sections at multiple locations along the emergency spillway.
- The original contract included approximately 155 CY of spillway-weir concrete removal and 45 CY of wall removal, establishing the substantial scale of the demolition and rehabilitation effort.
- Used saw-cut demolition methods along the tops of the spillway walls, where vibration and percussion-type removal equipment was specifically prohibited to protect the remaining structure.
- Constructed a new reinforced concrete overlay over the existing ogee spillway weir, restoring the deteriorated spillway surface while maintaining the original hydraulic profile.
- Reconstructed damaged portions of the left and right emergency spillway walls, including cracked concrete sections along the tops and sides of the existing abutment walls.
- The base contract carried approximately 155 CY of reinforced concrete for the spillway overlay and 45 CY for wall reconstruction.
- Used PennDOT Class A Modified Type II, air-entrained concrete with a minimum 28-day compressive strength of 3,300 psi, produced by a PennDOT-approved batch plant.
- Incorporated fiber-reinforced concrete to improve abrasion resistance and freeze/thaw durability in the rehabilitated spillway concrete.
- Installed ASTM A615 Grade 60 reinforcing steel with epoxy coating as required for the reinforced concrete restoration work.
- Drilled and epoxy-grouted reinforcing dowels into the existing structure to structurally integrate new concrete with the existing spillway and reconstructed wall sections.
- Installed No. 11 anchor bars grouted into bedrock to connect new concrete wall sections to the underlying rock foundation.
Project Description
Served as Prime Contractor directly to the Commonwealth of Pennsylvania Department of Conservation and Natural Resources (DCNR) for rehabilitation of the emergency spillway at Marsh Creek State Park.
Completed comprehensive rehabilitation of the existing concrete ogee emergency spillway weir and associated left and right spillway abutment walls, addressing deteriorated, cracked and spalled concrete.