By Cindy RileyCEG CORRESPONDENT

Located on a 266-acre site, the new $83.5 millionGreenfield water treatment plant for Huntsville Utilities willbe the most expensive construction project in the utility’s 75-year history. When completed in March 2018, the plant isexpected to treat 12 million gallons of drinking water perday.

“Demand for water from our system is regularly reaching80 percent of our capacity,” said Joe Gehrdes, director ofcommunications and public relations of Huntsville Utilities.“With water systems, 80 percent capacity demand tells youadditional capacity is needed to insure the supply can con-tinue accommodating demand, while also providing forgrowth. Discussion and design began after demand crossedthat threshold. It really just took that much time to put a proj-ect of this magnitude together.”

Huntsville Waterworks was founded in 1823. Hollowedcedar logs were used as pipes, and a wooden storage tankserved as a reservoir. It was Alabama’s first public watersystem. Today, the publicly-owned, not-for-profit utilityserves 90,000 water customers in Madison County.

As for the site chosen for the new plant — near the inter-section of Highway 431 and Guntersville Dam Road —Gehrdes called it a good fit.

“Huntsville Utilities has two existing surface water plantson the Tennessee River, so the position of this plant madeperfect sense from a redundancy and system reliability per-spective,” said Gehrdes.

The project will be funded with municipal bonds. Theproject includes a raw water intake structure, 42-in. (106.6cm) raw water main pipelines, a conventional settling WTPand a 48-in. (121.9 cm) finished water main pipeline.

“The design is necessary for surface water treatment.Additional treatment is required to meet current and futuredrinking water regulations,” said Gehrdes.

“The timeline for project completion is approximately 30months.

“A safe water supply is a foundational requirement for anycommunity. We must be able to supply safe drinking waterwith the necessary capacity to provide what our communityneeds now and in the future,” said Gehrdes. “We are incor-porating state-of-the-art security equipment into this project.Security is a very important aspect of any water supply.

“Water treatment of any kind is a huge responsibility.Water is essential for life, and our customers rely on us todeliver water that is dependable and safe. This added capac-ity will ensure that supply is always available, now and well

into our future.”Brasfield & Gorrie is serving as the general contractor.

According to Ben Harris, Brasfield & Gorrie division man-ager, a notice to proceed was issued in March, 2015.

“This project encompasses two primary construction sitesand over 10 miles of pipe lines. Right now we’re strippingtop soil and the mass excavation has started. There are alsomobilization activities underway installing laydown areas,construction entrances and temporary office space.”

There will be significant structural concrete work andover 10 mi. (16 km) of ductile iron pipeline work to com-plete the project. As for the raw water intake structure, Harrissaid it will require both on-shore and marine work that willbe challenging from a geotechnical and environmentalstandpoint.

“However, our team has extensive experience in thiswork. The raw and finished water pipelines will require sig-nificant coordination, because most of it is located on the

Alabama Department of Transportation’s right-of-way onHighway 431 and Guntersville Dam Road. Also, we expectto transport large earth moving equipment and pipelines tothe site. Our goal is to minimize disruption to the normalflow of traffic along this busy corridor.”

Approximately 150,000 cu. yds. (114,683 cu m) of dirt isbeing moved during the construction. Heavy machinerybeing used on the project includes three 150-ton (136 t)crawler cranes, as well as multiple excavators and associat-ed earth moving equipment.

The project consists of more than 20,000 cu. yds. (15,291cu m) of structural concrete and almost 2,000 tons (1,814.3t) of reinforcing steel. American Ductile Iron PipeCompany in Birmingham, Ala., will provide 23,000 linear ft.(7,010.4 m) of 42-in. (106 cm) and 35,000 linear ft. (10,668m) of 48-in. (121.9 cm) ductile iron pipe for the water mainsthat will be installed by Garney Construction, a subcontrac-tor to Brasfield & Gorrie. Shipment of pipe began in May.

“Our team is excited to work on this project, because theresult will provide quality drinking water for residents, andupon completion, it will support the growth and develop-ment needs of the city of Huntsville and surrounding areasfor years to come. A project of this type requires an experi-enced and dedicated construction team. We are fortunate towork with an experienced owner and world-class engineer-ing firm on this construction project,” said Harris.

Tetra Tech Inc., a provider of consulting, engineering, pro-gram management and construction and technical services,is overseeing the work.

“The single largest challenge to the project was maintain-ing the patience and focus on what has been a 10-yearprocess to get the project to construction,” said ChristianDunaway, Tetra Tech vice president. “We live in a veryshort-term world today, and the strategies that work in thatworld don’t always apply to projects of this scope, magni-tude and schedule.”

Tetra Tech was responsible for assisting HuntsvilleUtilities in the siting, permitting, design and constructionadministration of the project. Tetra Tech began workingwith Huntsville Utilities in 2005 to determine a suitable loca-tion for a new water treatment plant. Over the next decade,the team performed the site selection study, water qualitytesting, technology pilot studies, permitting, design and bid-ding services. The project is expected to last three years.

The work consists of four major components, includingthe raw water intake structure, the raw water main, the watertreatment plant and the finished water main. The raw waterintake structure is located on the Tennessee River, and is

Growing Demand Calls for $83M Water Treatment Plant

ALABAMA STATE EDITION A Supplement to:

Your Alabama Connection • Rich Olivier, Atlanta, GA • 1-800-409-1479

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Brasfield & Gorrie photoWhen completed in March 2018, the plant is expectedto treat 12 million gallons of drinking water per day.

July 222015

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Page 2 • July 22, 2015 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide

Huntsville Utilities Constructs Water Treatment Facilityresponsible for pumping water from thereservoir approximately three mi. (4.8 m)through the raw water main to the watertreatment plant. At the plant, the water willbe treated and then pumped approximatelyeight miles through the finished water mainto the existing Huntsville Utilities water sys-tem.

To determine the necessary treatmentprocesses, Huntsville Utilities and TetraTech began a year-long water quality studyto ascertain the makeup of the source waterit would treat at the new treatment plant.After that data was compiled and analyzed,the team began a series of pilot tests to deter-mine the most effective treatment options forthe new plant, and focused particularly ondisinfection byproduct control. Pilot testingincluded powdered activated carbon, granu-lar activated carbon, biologically activatedcarbon, MIEX, MIOX, fixed bed ionexchange, membranes and chloramines.Conventional treatment processes with theaddition of granular activated carbon waschosen.

Dunaway explained that 24-MGD will bethe treatment capacity of the plant after ithas been constructed and received its per-mits from the Alabama Department ofEnvironmental Management (ADEM).Split treatment granular activated carbon isthe treatment process chosen to control dis-infection byproducts.

“Where chlorine is used as a disinfectionagent, it can react with naturally presentcompounds in the raw water and produce arange of federal/state regulated disinfectionbyproducts,” Dunaway said. “The treatmentprocesses have been chosen to exceed allcurrent and future regulatory requirementsfor disinfection byproducts.

“Our job as a consultant is to work with

our client, to present solutions that meet theirfinancial constraints, schedule and all cur-rent and future regulatory requirements.Paramount to delivering a successful projectis to partner with our client, to listen to ourclient and to respond to our client like theyare our only client.

“Success hinges on having a client who'sknowledgeable in all aspects of water treat-ment, distribution and construction. From aproject technical perspective, it’s vital to putyour best team on the project, maintain teamcontinuity, break down the large tasks intosmaller manageable tasks and be prepared tohit change head-first.”

A number of the state and federal agencieshad to approve the project before construc-tion could begin, including the TennesseeValley Authority, the Army Corps ofEngineers and ADEM. Huntsville Utilitieswater supply superintendent Gary Bailey,who’s responsible for reviewing the designof the treatment plant and the pumping sta-tion and selecting acceptable equipment forthe water treatment plant, is working closelywith the contractor, Tetra Tech and ADEMto ensure the plant is built to specs and willfunction properly when completed. As theproject progresses, any problems will be dis-cussed with Huntsville Utilities and otherparties involved to find the best solution andkeep costs of the project within budget.

“With a project this large, a lot of time willbe spent with Tetra Tech and the contractoraddressing problems that will arise duringconstruction on a daily basis,” Bailey said.“One must stay closely involved in a projectof this nature, in order to work out issues asthey occur, rather than allowing them tosnowball into very costly problems. We willapproach this as a team effort to make surewe stay ahead of issues.”

Bailey said it’s crucial the plant be builtcorrectly and that provisions for future regu-lations be considered.

“Keeping costs under control is extremelyimportant to maintain our customers’ trust.This water plant will serve future genera-tions, and it’s a great responsibility knowingwhat we do now will affect this area formany years to come. The greatest challengeis to incorporate future growth and regula-tions while keeping the costs under controland delivering our customers a great prod-uct.

“Huntsville Utilities is very conscious ofthe cost of the plant and we have workedvery hard to make sure resources have beenused wisely. The quality of drinking water issomething we will not compromise. Havinga safe, adequate supply of water will helpour area continue to grow, which providesjobs for the residences. Delivering safe

drinking water to our customers is a 24/7,365 job, and one that is not taken lightly. Weknow we’re doing our job when customersturn on their faucets and always have a plen-tiful supply of safe drinking water, whilenever giving it a second thought.”

Huntsville Utilities is currently reachingthe capacity of its water system during peakperiods. Bailey said the new plant will pro-vide the additional capacity needed for manyyears to come, while continuing to allownew industries to locate in Madison County.

“The plant is being designed so that it caneasily be expanded in order to meet futuregrowth for our customers. The plant will alsoadd more redundancy to our water supply sothat we can make sure that our customershave a continuous supply of safe drinkingwater. This plant will be our third surfacewater plant on the Tennessee River and willallow a plant to be taken off line for mainte-nance and / or upgrades while still supplyingour customers with water.

“I think our customers’ support ofHuntsville Utilities building a new waterplant speaks highly of them. In the early1960s, it was decided to build a water plantthat has allowed our area to grow while pro-viding customers with a plentiful supply ofsafe drinking water. Many areas of the coun-try are facing water shortages and are forcedto limit water to industry and customers,which has caused the costs of water to sky-rocket. The decision to build a new plant willnot only meet our current demands, but alsoenable this area to continue to grow and pro-vide jobs for our children and grandchil-dren.”

(This story also can be found onConstruction Equipment Guide’s Web site atwww.constructionequipmentguide.com.)CEG

PLANT from page 1

Brasfield & Gorrie photoLocated on a 266-acre site, the new $83.5 million Greenfield water treatment plantfor Huntsville Utilities will be the most expensive construction project in the utili-ty’s 75-year history.

Tetra Tech Inc. rendering A rendering of the completed Huntsville Utilities water treatment plant.

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • July 22, 2015 • Page 3

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Page 6 • July 22, 2015 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide

The Alabama State Department of Transportationreceived bids for transportation-related improvementprojects.

Following is a list of some of the projects let.

County: ElmoreContract ID: 20150130008Project: Resurfacing and traffic stripe.Location: Various locations.Contractors and Bid Amounts:

• Asphalt Contractors Inc. — $3,953,110• Wiregrass Construction Company Inc. — $4,371,228• Midsouth Paving Inc. — $4,475,559

County: MobileContract ID: 20150130010Project: Widening, drainage improvements, resurfacing,and stripe. Location: On Dawes Road from Grand Bay-Wilmer Roadto Three Notch Road.Contractors and Bid Amounts:

• John G. Walton Construction Company Inc. —$2,128,240

• Mobile Asphalt Company LLC — $2,293,914• H. O. Weaver & Sons Inc. — $2,507,707

County: MobileContract ID: 20150130011Project: Widening, drainage, resurfacing, guardrail andtraffic stripe.Location: On CR-70 from CR-5 to 1200 ft. west of ElizaJordan Road.Contractors and Bid Amounts:

• John G. Walton Construction Company Inc. —$3,055,916

• H. O. Weaver & Sons Inc. — $3,212,413• Mobile Asphalt Company LLC — $3,412,593

County: EtowahContract ID: 20150130020Project: Bridge replacement and approaches (grade, drain,base and pave).Location: On Wesson Gap Road over Big Wills Creek.Contractors and Bid Amounts:

• Jones Bros. Inc. — $2,197,094• Dement Construction Company LLC — $2,257,110• The Bridge Builders Of Alabama LLC — $2,560,446• Wright Brothers Construction Company Inc. —

$2,591,281• McInnis Construction LLC — $3,034,843• Scott Bridge Company Inc. — $3,071,272

County: MorganContract ID: 20150130026Project: Bridge replacment and approaches.Location: On CR-125 (Kirby Bridge Road) over WestFork.Contractors and Bid Amounts:

• Miller & Miller Inc. — $2,250,688

• Riley Bridge Company Inc. — $2,381,476• Dement Construction Company LLC — $2,561,019• Jones Bros. Inc. — $2,624,345• Maloney Construction Inc. — $2,915,802

County: MonroeContract ID: 20150130029Project: Intersection realignment, resurfacing and trafficstripe.Location: On CR-20 from SR-41 to the city limits ofMonroeville.Contractors and Bid Amounts:

• H. O. Weaver & Sons Inc. — $1,245,255• Midsouth Paving Inc. — $1,375,348• John G. Walton Construction Company Inc. —

$1,432,343

County: AutaugaContract ID: 20150130031Project: Widening, resurfacing, and traffic stripe.Location: On CR-57 from the intersection of CR-40 to theChilton County Line.Contractors and Bid Amounts:

• Asphalt Contractors Inc. — $1,535,139• Midsouth Paving Inc. — $1,680,947• Wiregrass Construction Company Inc. — $1,976,055

County: ChoctawContract ID: 20150130034Project: Resurfacing and traffic stripe.Location: On CR-9 and CR-24.Contractors and Bid Amounts:

• Mobile Asphalt Company LLC — $3,439,850• H. O. Weaver & Sons Inc. — $3,606,440

County: ClarkeContract ID: 20150130035Project: Resurfacing and traffic stripe.Location: On CR-44 (Tallahatta Springs Road) from SR-69 to the Thomasville City Limits.Contractors and Bid Amounts:

• H. O. Weaver & Sons Inc. — $1,402,478• Mobile Asphalt Company LLC — $1,502,966

County: St. ClairContract ID: 20150130036Project: Planing, resurfacing and traffic stripe.Location: On CR-42 from SR-7 to Steele Gap Road andon CR-22 from SR-53 to CR-21.Contractors and Bid Amounts:

• McCartney Construction Company Inc. —$2,466,735.

• Good Hope Contracting Company Inc. — $2,713,271• Midsouth Paving Inc. — $3,875,974

County: ShelbyContract ID: 20150130056Project: Resurfacing and traffic stripe.Location: On I-65 south of SR-3 (U.S.-31) (MP 237.600)to south of CR-52 (MP 241.800).Contractors and Bid Amounts:

• Dunn Construction Company Inc. — $7,470,700• Wiregrass Construction Company Inc. — $7,985,438• Midsouth Paving Inc. — $9,296,976

Montgomery • Jefferson • Talladega • Calhoun • Russell • Walker • Lawrence • Dekalb • Morgan • St. Clair • Tuscaloosa • Morgan • Shelby• Bibb •Hale • Fayette • Marion • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • St. Clair• Chilton • Escambia• Montgomery • Jefferson • Russell • Fayette • Conecuh • Coffee • Geneva • Montgomery • Jefferson • Talladega •Bibb • Coffee • Calhoun • Russell • • Walker• Lawrence• Dekalb • Morgan • St. Clair • Tuscaloosa • Bibb• Hale • Fayette • Monroe •Clarke • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • Montgomery • Jefferson • Talladega

Alabama…

‘The Yellowhammer State’ Highway Project Lettings

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • July 22, 2015 • Page 7

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