As the temperatures outside are heating up, so is the construction at Water Treatment Plant 2! Significant progress, as shown below, has been made over the last few months with the completion of the new water storage tank and advancement of the chlorine dioxide contact basin.
Water Storage Tank Replacement. June brought the end of the tank construction – another milestone achieved on the project! Wire-wrapping of the tank was completed, an off-white coating was painted over the exterior shotcrete surface, and the inside of the tank was disinfected. We took a sneak peak at the completed interior of the tank on Facebook; if you missed that video, you can catch it here .
All that’s left to be done on this project is to restore the area around the tank, which crews will complete during the fall seeding season.
Left: Tank interior showing a baffle wall (left) and the outside wall (right). Right: The finished tank complete with final coating, ladders, and hatches.
Chlorine Dioxide Disinfection Facilities. Construction of the contact basin has begun. This basin will provide disinfection of the untreated water to meet regulatory requirements. Last month, the tank slab was poured; it was large enough that it had to be poured at two separate times. This month, the basin is going vertical with construction of the exterior walls, which are 30 feet tall. Work also continues on the chemical containment boxes that will be part of the adjacent building.
Top Left: The east wall of the contact basin is being formed and rebar placed. Bottom Left: An up-close look at the contact basin slab rebar. Right: A view of the disinfection project progress from the top of the existing lime silos.
Lime Feed Improvements. The foundations for the lime feed building are nearly complete. The square pier caps, which will transfer weight from the lime silos to the underground piers, were poured last month. Strip footings that support the building were also constructed. This month, underslab pipes and electrical conduit are being installed in preparation for completion of the building’s floor slab.
An overview of the progress of the new lime feed building.
Despite record rainfall for the month of May, construction is forging ahead at Water Treatment Plant 2. Below is what we’ve completed this month.
Water Storage Tank Replacement. After all panels were placed for the walls and roof, the spaces between the panels were filled in with concrete. Crews then sprayed the outside of the tank with a layer of shotcrete, or concrete that is sprayed during application, and began wrapping and tightening the tank with high-strength steel wire. The wire ensures the panels remain compressed together for a durable tank structure. The video shows the process used to wire-wrap the tank.
Left: The top third of the tank has received a layer of shotcrete and has been wire-wrapped. Right: The top two-thirds of the tank has been wire-wrapped and received another layer of shotcrete. The bottom third of the tank is awaiting the wire-wrapping process.
Basin Modifications. Basin 3 work is complete, and the basin has been put back in service just in time for the peak water use season. Hopefully you caught our two videos on Facebook last week where we took an inside look at the basin equipment then filled it up to start treating water.
The video below shows what the center of the basin looks like when in operation. Lime is added and mixed in the center, then flows to the outside of the basin where it spends a couple hours or more and particles settle to the bottom. The treated water comes into the middle ring and travels on to the next process.
Work on this part of the project will be suspended over the summer and will begin again in September with work on Basin 2.
Left: A view of Basin 3 under the center structure, where lime is mixed with the untreated water. Middle: A view of the Basin 3 equipment from inside the structure. Right: Basin 3 back in operation.
Chlorine Dioxide Disinfection Facilities. Work continues on the below-grade concrete structures that house flow meters and chemical containment. This month, work began on the chemical containment boxes that will be inside of the building; these containment boxes will be used for two chemicals that are used to generate chlorine dioxide. The slab was poured, walls are being formed, and reinforcing steel is being placed.
Chlorine dioxide disinfection facilities under construction.
Lime Feed Improvements. This month the pier foundation that will support the new lime silos was completed. Eight piers were drilled 40 feet deep to bedrock, then filled with reinforcing steel and concrete.
Left: The drilling rig starts its first pier of the project. Top: The concrete pump truck fills a pier hole with concrete. Bottom Left: A 40-foot deep pier hole. Right: A pier completed with reinforcing and concrete.
Construction is in full swing with all four projects underway. Here’s what we’ve been up to in April.
Water Storage Tank Replacement. While high winds hampered the tank construction for about a week in April, the precast wall panels are now being put into place and the structure is starting to look like a tank. A large crane is on-site to “fly” the panels into their designated locations. Next month, concrete will be poured between the panels to complete the walls and roof of the tank.
The new 36-inch bypass pipe around the tank is complete – our first milestone on the project. With this bypass line we are able to operate our membrane treatment process again, which is important as water use is ramping up with the warmer temperatures.
Top Left: Tank construction crews finish recently-poured concrete for a tank dome (roof) panel. Bottom Left: All interior walls and half of the exterior walls have been placed. Scaffolding is in place for construction of the tank dome. Right: A large crane is used to place the first panel of the tank before high winds halted the construction for a week.
Basin Modifications. Painting of Basin 3 is complete. The basin now looks fresh and clean, and more importantly, the new paint will protect the steel equipment from corrosion and rusting. New equipment in the center of the basin will be installed within the next couple of weeks. Following that installation next month, Basin 3 will be put back into operation and ready for the peak summer season.
Basin 3 before painting (left) and after painting (right).
Lime Feed Improvements and Chlorine Dioxide Disinfection Facilities. Work is forging ahead on the disinfection structure. The below-grade concrete structures that house flow meters and chemical containment are underway. Base rock has been placed for the new lime feed building and the pier foundation will soon be constructed.
Chlorine dioxide disinfection facilities under construction.
Left: Base rock has been laid and compacted for the lime feed building. Right: Rebar has been formed into cages for the pier foundation, to be drilled in early May.
With the warmer March temperatures work on the Water Treatment Plant 2 project has ramped up! While we aren’t up to full speed yet, it’s fun to see some of the new facilities get started. Here is what we have accomplished in March:
Water Storage Tank Replacement. The floor of the tank is being prepared for concrete with formwork construction and rebar placement. The interior and exterior walls of the tank, which are built on the ground as individual panels that will later be tilted into place, have also been formed and crews are placing rebar. Concrete will be poured for the floor and wall panels over the next few weeks.
The new 36-inch bypass pipe around the tank is approximately half done. The next step is for the pipe crew to connect to the existing 42-inch pipe, which resides approximately 10 feet below ground, and lay pipe to the north.
Top: The floor of the tank is ready for rebar placement, followed by concrete. Bottom Left: A tank wall panel has had rebar placed and is ready for concrete. Bottom Right: Crews have located where the 36-inch diameter bypass pipe will tie into the existing 42-inch diameter piping and read to lay pipe from the connection.
Basin Modifications. Painting work continues on Basin 3. The existing paint was sandblasted from the equipment and the prime coat of paint has been applied. Over the next two weeks, the second and third coats of paint will be applied.
A look inside at the primer coating of Basin 3. The primer coat is red, the second and third coats will be a light blue color
Lime Feed Improvements and Chlorine Dioxide Disinfection Facilities. Dirt fill to raise the elevation of the ground is resuming with the warmer and drier conditions. The lowest concrete floors of the chlorine dioxide building have also been excavated out and are being prepared for concrete.
Crews placing rebar for the floor of part of the new chlorine dioxide building. This part of the building, once complete, will house a flow meter that will measure the amount of flow coming into the plant from the water supply wells.
In April, we look forward to the water storage tank taking shape with erection of the interior and exterior wall panels; completion of the painting of Basin 3; completion of the site dirt fill for the Lime Feed and Disinfection facilities (weather permitting); and continued progress on the new chlorine dioxide building.
January and February have been slow months for the project thanks to the weather! The rain, snow, and cold temperatures have hampered, but not stopped, the construction progress. Here is a brief overview of what has been accomplished over the last month:
Water Storage Tank Replacement. This month, crews have been working to dig a hole approximately 10 feet deep and 80 feet wide to fill with gravel as a foundation for the new tank. Work has also begun on a 36-inch pipeline around the tank that will allow for operational flexibility during construction and beyond when the tank is out of service for maintenance.
Preparation of the site and foundation for the new concrete water storage tank.
Basin Modifications. Demolition work was completed on Basin 1. This basin is the oldest basin at the plant and will not be used in the future; therefore, the old equipment was removed. The concrete structure will remain in place to be repurposed in the future.
Metal repairs on the equipment inside Basin 3 were completed. Following the repairs, a tent over the basin was constructed for the purpose of containing material and keeping the inside of the basin warm for painting. Over the next two months, the existing paint will be sandblasted off the equipment and it will be repainted.
Basin 3 is covered with a tent for sandblasting and painting of the equipment inside.
Lime Feed Improvements and Chlorine Dioxide Disinfection Facilities. Before these facilities can be started in earnest, dirt must be brought in to raise the elevation of the west side of the site five to eight feet. This process requires dry ground conditions and temperatures above freezing. January and February have been wet and cold with only about two weeks’ worth of good weather for compacting the dirt; therefore, only about 20% of the new dirt has been placed.
Dirt fill for new Lime Feed and Disinfection buildings.
In March, we look forward to starting on the new concrete water tank, painting of Basin 3, and completing site dirt fill for the Lime Feed and Disinfection facilities if the weather cooperates.
In December 2018, the City of Olathe Public Works Department started on exciting upgrades at Water Treatment Plant 2 (WTP2.) Originally built in 1964 and last expanded in 2006, WTP2 provides drinking water to approximately 135,000 residents in Olathe and surrounding areas.
The City has partnered with Crossland Heavy Contractors, Black & Veatch, and HDR to design and construct approximately $17 million of upgrades at WTP2 over the next two years. These upgrades will rehabilitate critical treatment plant infrastructure, improve the taste and quality of the drinking water, and ensure reliable operation into the future for delivering delicious drinking water to all customers.
The major components of the project are:
- Lime Feed Improvements. Lime is added to the treatment basins to soften the water. New lime storage silos and a building to house associated equipment will replace existing silos and equipment. The new facilities will provide improved safety for staff who operate and maintain the system and will ensure reliable operation of the treatment process.
- Basin Modifications. The plant has three treatment basins that, with the lime addition, soften and remove particles in untreated water. Two treatment basins need equipment replacement, while equipment in the third basin will be repaired and repainted. These improvements will result in improved treatment efficiency and will ensure the integrity of the softening process now and into the future.
- Water Storage Tank Replacement. The steel water storage tank will be demolished, and a new concrete storage tank will be built in its place. The new concrete tank will have an extended service life to store treated water until it is pumped into town.
- Chlorine Dioxide Disinfection Facilities. Disinfecting drinking water is an important step, removing microbial pathogens that may be present in untreated water from the Kansas River. New chlorine dioxide disinfection facilities will replace existing disinfection facilities. The new facilities will ensure that all disinfection processes comply with federal drinking water regulations, while also improving the taste and odor of the drinking water.
The City of Olathe takes pride in providing high quality water to all customers, and these upgrades will ensure that remains the case into the future. Check back regularly for updates as the project progresses, and be sure to follow the City of Olathe on Facebook, Twitter, and Instagram for behind-the-scenes looks at construction activities!