Grand Glaize Flood Protection

Recent flooding from the nearby Meramec River provided a need to enhance the protection of this wastewater plant responsible for treating over 14 million gallons of wastewater per day in Valley Park, MO. KCI’s scope included 586 feet of sheetpile and concrete wall along with 615 feet of new earth levee to protect the plant, which worked in concert with 380 feet of new site drainage system piping and 7 cast-in-place concrete storm structures.

Deer Creek Pump Station

Construction of 1 Wet Well and 2 Dry Wells, each 180 feet deep and 36 foot diameter, inside shafts drilled and shotcreted by others, to facilitate pumping storm and sanitary flows. Dry Well and Wet Well Buildings top the 3 shafts, with associated electrical, mechanical systems and controls for a new pump station site in Shrewsbury, MO.

Lower Meramec Corrosion & Humidity Improvements

A 223 foot deep pump station built near the confluence of Mississippi and Meramec Rivers had experienced groundwater infiltration for over 12 years when KCI won the contract to begin mitigation of this groundwater. The water was causing significant corrosion and humidity issues, so over 34,000 square feet of the outer walls were treated with Xypex waterproofing, designed to seal the concrete from the inside. The bottom 100 feet of the pump station was lined with scaffolding for access for Xypex installation as well as piping and HVAC replacements with less corrosive materials.

Lemay Wastewater Treatment Plant Disinfection

In order to comply with Federal Regulations regarding the quality of water that is discharged after treatment at a wastewater plant, MSD was required to construct this plant addition, with KCI winning the competitive bid. One of the largest systems in the area, this upgrade needed to have the ability to treat a peak flow of 240 Million Gallons per Day of wastewater. The project scope included a 2,200 sf Chlorination Building, a 23,000 sf UV & Disinfection Facility, and installation of 144″ diameter Prestressed Concrete Pipe to connect the new UV Facility to existing junction chambers. The new UV…

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Taum Sauk Pump Back Modifications

When the Taum Sauk Reservoir was rebuilt after dam failure, it was constructed of roller compacted concrete that was capped with traditional cast-in-place concrete. Periodic joints allowed for expansion and contraction, and were designed to leak until calcium content from the water sealed the joints. The water was routed to a holding basin and pumped out periodically, but during heavy rains the basin flowed into the Ozark Mountains. The high calcium content of this water was bad for the environment, so Federal Regulators required Ameren to contain the water, which was the scope of this project. KCI connected to two…

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Columbia Wastewater Treatment Plant Improvements

The expansion of the Columbia Wastewater Treatment Plant was to achieve many goals: Increase capacity from 13 MGD to 26 MGD, Upgrade the existing outdated facility & processes, Increase Biosolids-Handling capabilities and Provide better odor control. All were achieved while also adding energy efficiency to the plant and reduce consumption: Solids are now further dewatered, reducing local truck traffic through adjacent neighborhoods; New methane gas cleaning system and associated heat and power system is 26% more efficient; High efficiency blowers installed reduces annual energy consumption by 26%. The expanded plant includes four Clarifiers, two Aeration Basins, two Pump Stations, a…

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Cape Girardeau Wastewater Treatment Facility

The City of Cape Girardeau was outgrowing the wastewater plant built in 1962, and due to sinkholes that developed in the area of the existing plant, expansion was not feasible. In July 2012, KCI was the low bidder on the new plant and began construction in August 2012 on the plant with capacity of 11 Million Gallons per Day during dry weather and 50 MGD during wet weather. The new facility includes a 40 foot deep Influent Pump Station, Screening and Grit Removal operations, and a 250 foot square Sequencing Batch Reactor, UV Disinfection, Sludge Storage and Processing facility, and…

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MU Power Plant Cooling Tower Replacement & 480V SUS Replacement

In order to accommodate a new cooling tower and electrical upgrades within the existing power plant, both of the major upgrades were broken down into five phases of work. Cooling tower work consisted of relocation of site utilities and parking lot, followed by building the cooling tower foundation, which bears on drilled piers and substantial grade beams to allow it to remain in place should all subgrade material disappear. After the new cooling tower was built by others, the four existing cooling towers were demolished in four phases off the 100 foot tall power plant roof. While the cooling tower…

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Washington Wastewater Treatment Plant Expansion

In order to facilitate the forward thinking of the City of Washington, Missouri, officials gained public support for bonds to fund the largest public works project in the city’s history, with KCI winning the bid for the construction. The plant is classified as a “compact plant” because the plant footprint is fairly small compared to other facilities. Due to the need to treat 4 MGD and eventually 6 MGD on a restricted site, the plant was designed as a Vertical Loop Reactor system which was the first of its kind built in Missouri. Additionally, the new plant includes a “cannibal”…

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Creve Coeur Pump Station

An aging pump station needed replacement due to general deterioration and because it was undersized for future growth in the area. The new pump station, situated on the same site as the existing station, was a few hundred feet from Creve Coeur Lake and at 40 feet deep is approximately 30 feet below the water table. KCI developed a sheetpile shoring system with internal walers and tie-backs, and coupled that with a dewatering system utilizing 14 deep wells that ran around the clock for ten weeks. After sheetpile installation, the entire site was vibrocompated prior to excavation, and the pump…

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Holcim Mill & Corrective Additives Foundations

The new cement plant along the Mississippi River in Ste. Genevieve was developed on a 1,700 acre site to ultimately produce four million metric tons of cement annually. KCI was selected to construct the first concrete package consisting of foundations for the Clinker Cooler Structure, four Cement Mills, two Raw Mills and two Coal Mills. All of these structures were excavated into solid rock and constructed with over 19,000 cubic yards of concrete and 1,400 tons of rebar, over an approximate 9 month duration with over 100 KCI tradesmen on site at one time. Additionally, KCI installed the equipment foundations…

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Palm Sewer Replacement

An arched concrete sewer built in 1930 was in need of replacement after numerous repairs throughout the years were also failing. KCI was the successful low bidder on the project to replace this sewer with a new 18′-0″ by 14′-4″ reinforced concrete arch sewer, located at the Terminus of Branch Street on the West Bank of the Mississippi River in north St. Louis. The project schedule required completion within two years, as work was dependent on the river being below stage 10, which historically only happens a few months each year. Construction started with temporary shoring installation, excavation and demolition…

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Lakeside 370 Levee Pump Stations

Despite almost 9 months of politically related delays prior to starting work, KCi began work in fall of 2005 on two new pump stations to accommodate the new 100-year levee being installed to facilitate new development. Construction of the two concrete pump stations was completed in the 12-month schedule, while dealing with a constantly flooding site directly underneath high-voltage power transmission lines. One station was built into the new 100-year levee built by others, and one station was cut into the 30-year Dardenne Creek farm levee. “I would like to thank KCI Construction for the teamwork demonstrated in the construction…

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Lower Meramec Lift Station

It isn’t uncommon to build a 20-story structure in St. Louis. It is uncommon to END at grade instead of beginning there. KCI did just that, building two concrete shafts to over 200 feet below grade to pump to a new wastewater treatment plant. This unique project offered constructability and scheduling problems, but also included safety challenges involved in deep, vertical construction. All access for construction was from the “top”, with all workers being hoisted to their work elevations via cranes and man baskets, at one point requiring 13 cranes around a single 90-foot diameter shaft. “We thank KCI for…

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