Archives
Maryland Heights Commerce Center Pad Prep
KCI Earthwork operations started on this new site development in 2022, which is a small portion of a recently started 121 acre development that will contain approximately 1.4 million square feet of office flex/office distribution buildings in previous farm ground off Highway 141 in St. Louis County.
Wright City Park
KCI was awarded the first phase of this new park in a Wright City, Missouri neighborhood that will eventually feature four baseball fields and associated buildings and parking areas. Project scope included clearing the site for earthwork, installation of underground utilities, grading of the site and installation of retaining walls to accommodate the future development.
FedEx Distribution Facility
Pad preparation/stabilization along with earthwork and utilities to facilitate construction of a new 450,000 square foot tilt-up warehouse for FedEx. Project is located off Premier Parkway & 370 and now serves as a FedEx distribution hub for the St. Louis Area.
MHS Hanger
To support construction of a new hangar inside St. Louis Lambert International Airport, KCI’s scope of work included all sitework & underground utilities. KCI worked with Lambert airport officials to facilitate hauling in over 26,000 cubic yards of material through active taxi ways.
National Cart
Removal of existing concrete & asphalt paving followed by building pad stabilization, sitework and storm sewers to facilitate construction of a 60,000 square foot facility addition to manufacture shopping carts.
Warrenton Pool Park
KCI performed clearing of a 15 acre site and mass earthwork to facilitate construction of a new park featuring indoor pool, walking trails, dog park, and 18 hole disc-golf course located off Warrior Avenue & State Hwy 47 in Warrenton, MO.
Riverside RV Park
St. Charles County purchased an aging boat storage and ramp launch facility with a vision, and that vision came to reality in late 2021 with the completion of a unique outdoor recreation area. This Park features concrete camping pads for thirteen RV and five campers with electric hook ups, sanitary dump station, free boat ramp to the Mississippi River and spaces for 59 boat trailer storage, and a scenic overlook platform at the confluence of the River with Dardenne Creek.
Route 67 Reconstruction
Route 67 in West Alton experienced flooding with the rise of the Mississippi River, at times shutting down the southbound lanes that would be inundated. KCI was awarded the two-year project in summer 2021 to raise these lanes approximately 10 feet in elevation and then re-align and concrete pave north and southbound Route 67, a key artery between Alton, Illinois and St. Charles County in Missouri.
Route 61 Troy Bridges
Existing bridges built in 1971 had been closed 5 times in the last 10 years due to flooding of the Cuivre River, and KCI began replacement of bridges and associated highway paving in Spring 2019. New bridges were built 5 feet higher than the existing, and bear on drilled shafts and steel pile. Bridges were constructed alongside the existing alignment to avoid traffic interruption, and then 150,000 CY of earth fill and 41,000 SY of concrete paving installed for the new alignment prior to removal of the original bridges.
Park Over the Highway
CityArchRiver 2015 had a goal of uniting our region and one of the world’s most recognizable icons with another of our greatest assets – the Mississippi River. KCI executed work for both MoDOT and the National Park Service to achieve this goal. We first completed the bridge that allowed visitors to walk from the Old Courthouse to the Arch grounds to the riverfront on one continuous greenway, without a curb or stair step in their way. The project scope included rerouting of traffic at the Eads Bridge and Washington Avenue and a new exit from I-55 North/I-70 West onto the…
Loop Trolley Track
Description – In an effort to further revitalize an area of University City and the City of St. Louis, vintage trolley cars will soon be running on a new 2.2 mile long track system from the West end of the Delmar Loop to the Forest Park History Museum, by running East on Delmar and then South on DeBaliviere and back. Streetscape modifications will include boarding stations, landscaping, lighting and signals to further enhance this area. As part of the project, KCI will also replace a 4-span bridge over the live MetroLink tracks near DeBaliviere and Forest Park Avenue.
Metrolink Facilities 5 Extension
Metrolink is the St. Louis metropolitan region’s light rail system comprised of 37 stations and 46 miles of track which serve the St. Louis area and St. Claire and Monroe counties in Illinois. In 2003, the rail system was expanded to the southwest side of St. Louis, and KCI was awarded a 1.3 mile section of this expansion. Along with site clearing and demolition of existing structures, KCI constructed five new bridges from 120 feet to 2,400 feet in length, setting 83 concrete and 88 steel bridge girders in the process. These bridges spanned Interstate 44, two railroads, Big Bend…
St. Louis County Courts Project
The existing County Courts building, built in the late 1960’s, was reviewed in 2008 by a Blue Ribbon Panel that subsequently determined a need for major upgrades to the crumbling and outdated facility. After years of political debates and voter rejection of funding measures, KCI was selected in September 2013 as the Best Value to construct the renovations and additions. KCI received the highest technical score for the design-build proposal, and is teamed with Fentress Architects as the lead design firm. The project of approximately 380,000 square feet will consolidate the Family Court, including Juvenile Detention, with the Circuit Court…
Page Olive Connector
KCI submitted the highest scored technical proposal for this design-build project, and also submitted the lowest initial bid that was 10% under budget. We then worked with the owner to further enhance the project without cost increase. The project consists of a six-lane highway comprised of 60% bridges and 40% pavement above the area floodplain. KCI’s design-build team was prepared upon project award, and began construction three months after award, working through the harsh winter of 2010 and subsequently achieving project completion months ahead of schedule. We exceeded the workforce diversity and DBE subcontracting goals, while working over 150,000 manhours…
Mid-Campus Graham-Defoe Housing
KCI teamed with IAA for this design-build residential housing project at University of Missouri, and was selected for this challenging, fast-paced project based on overall value to the owner. IAA and KCI developed design documents from the bridging documents supplied by the owner, to construct 190,000 square feet of new space and 80,000 square feet of renovation, of which 90% is residential dorm space. Due to constraints of a two-year schedule and tight budget, a low-cost and fast-paced construction of structural stud framing and slab-on-decks was chosen, with a brick and EIFS facade. With special working hours at times to…
Ft. Leonard Wood Training Barracks Upgrade 09
KCI teamed with IAA on this design-build project that included renovations and additions to Barracks 816, 817 and 818, as well as Dining Facility 820 and Battalion Headquarters 822. The LEED Silver project, which was awarded to our team based on the Best Value to the government, included seismic rehabilitation, progressive collapse mitigation and ATFP measures. Renovation was based on complete demo of building interiors, as well as repairs & replacement of masonry veneer and exterior windows and roofing. Site improvements included typical utilities and sidewalks, as well as over 5000 feet of ATFP barrier concrete wall and force protection…
Drug Enforcement Agency Building
The local branch of the Drug Enforcement Agency was spread out over several offices around the St. Louis metropolitan area, and needed to consolidate into one facility. KCI teamed with developer Harwood and Associates and designer Cannon Design to design, construct and lease to GSA a new state-of-the-art facility to accomplish this goal. This five story steel frame & precast building sits above a two story underground parking garage. The majority of the building houses office space, and is a high security building with restricted gate access for vehicles and all but the entrance door controlled by card reader access.
UMSL West Campus Parking Garage
The University of Missouri – St. Louis gave preliminary design/build guidelines with layouts and their budget, giving teams flexibility to come up with innovative ways to deal with vehicle circulation and appearance. Original plans called for 626 parking spaces, but KCI offered a plan with 670 spaces. Instead of an average garage, our team designed a front entrance that created an architectural tie-in to the campus with a precast, two-story arched entrance, a portico with serpentine wall and an attention-getting green canopy roof. All of this was provided while beating the owner’s budget by almost $500,000. “The custom-designed parking garage…
MSD ORS Phase II Gate Replacement
A system of levees, floodwalls and pump stations along the Mississippi River in St. Louis protect the City from river flooding, but at the same time facilitate the need for storm water to be pumped out of the City sewer systems. KCI was deemed the best value to replace a small portion of this system, and in 2020 began design to replace 12 stainless steel roller gates, 5 slide gates, and 2 bar screens at the Riverview and Baden Pump Stations in North St. Louis. Work included structure reinforcing, replacement of 21 gate actuators, and coordination with volatile river levels…
St. Peters Pump Station No. 3
An aging pump station in Old Town St. Peters struggled to keep up with storm water that flowed to this low point in the City, so in 2016 the City designed and awarded the project to replace the pump station with a larger version. KCI shored and excavated around two-6 foot diameter concrete storm pipes, incorporated them into the next structure, and then removed sections of them so that all storm water was captured at the new station and pumped over the levee into Dardenne Creek.
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…
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…
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…
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…
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”…
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…
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…
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…
MU East Campus Plant Growth Facility
New Greenhouse for the University of Missouri that involved relocation of site sewers that were over 50 feet deep prior to construction. The East Campus Growth Facility consists of 24 greenhouses, many of which are extended height and all with HID lighting and RO irrigation water. Cold storage facilities, seed processing and drying rooms, a root washing area, shared lab space and an isolation suite complete this impressive structure.
MRO Hangar
American Airlines had a 22,000 SF maintenance facility at the Springfield-Branson National Airport that they had outgrown, and in 2020 selected KCI Construction to build a larger modern MRO (maintenance, repair & overhaul) facility that could house three Embraer-175 jets, which are regional aircraft that can hold 88 passengers. The pre-engineered building predominantly contains maintenance & repair space for planes accessed through 215 ft wide x 35 ft high doors, as well as offices and training spaces.