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What We Do

We remain one of the more diverse contractors in the area, with the expertise and ability to successfully perform on a wide range of projects. Any one of us can be found working on a design-build multi-story building one day, then a wastewater plant following, and highway infrastructure after that.

A sample of these various projects can be found by clicking on the tabs above. Current and Completed Projects are included in each of the project types.

Touhill Performing Arts Center

This center serves as both an entertainment venue and learning laboratory, with a 1,630 seat performance hall and a 200 seat multipurpose music and theater hall. The theater is acoustically correct while sitting in a St. Louis Lambert Airport flight path and alongside Metrolink light-rail tracks. The concrete framed building was built during a city-wide concrete strike, and was constructed with site constraints of Metrolink on one side, and constant vehicular and pedestrian traffic on the other sides. The majority of the space is dedicated to theater space, with areas of offices and a highly technical control and data center. Ornate details consume the interior theater, with site development of brick paver walks, street pavement details and ornate retaining walls.

"It was a good construction project. Good project team, good subcontractors, good coordination, good communication, and pride and passion for a well designed building."
Sam Darandari - University of Missouri St. Louis

Vitals

123,000 SF

University of Missouri - St. Louis

General Contractor

$45,500,000

Bid Build

June 2003

Farnsworth Group

Butler Carlton Engineering Building

This project involved a three-phase addition and renovation of the existing Civil Engineering building on the University of Missouri at Rolla campus. Phase one included a steel frame addition to the existing building and relocation of the existing facilities into the new building. Remodeling of the existing building and opening it for use completed phase two of the project. Construction of a three story link between the original and new buildings finalized phase three and the entire project, which included classrooms, offices, laboratories and lecture halls. The large atrium was designed as a teaching tool, and features exposed structural, mechanical, and electrical elements for students to see and study as they walk to and from their classes.

Vitals

150,000 SF

Missouri University of Science & Technology

General Contractor

$17,930,000

Bid Build

July 2000

Hastings & Chivetta

Columbia Public Library

To make way for a new library, KCI was hired to demolish the majority of the existing facility, leaving little more than a portion of the foundation and one wall. The new facility was then built around these remaining elements, with design provided by internationally renowned architect Hardy Holtzman. The project was initially awarded with major portions of the exterior excluded, and subsequently KCI and Hardy Holtzman worked together to provide the designed building skin within the owner's budget. The facility consists of administrative offices and library space, constructed of two stories of masonry, steel and structural timbers.

Vitals

100,000 SF

Columbia Library

General Contractor

$19,020,000

Bid Build

August 2012

Hardy Holtzman

Waynesville High School

Construction of a new high school for the Waynesville R-6 School District included a theater, gymnasium, classrooms and administrative spaces. The four-level facility was constructed of a precast shell on structural steel framing and load bearing CMU, with a combination of standing seam and membrane roofing. Despite substantial weather delaying the critical path of the project schedule, KCI was able to work with the owner and architect to mitigate the effect on the schedule. The result was completion 67 calendar days ahead of the contract completion date, which allowed the owner to move into the new building over winter break instead of waiting until summer.

"I highly recommend (KCI) for whatever type and/or size of project and believe you will be thoroughly satisfied with their workmanship, quality of work and their staff."
Ed Musgrove - Waynesville Superintendent

Vitals

250,000 SF

Waynesville R-6 School District

General Contractor

$16,270,000

Bid Build

December 2003

Winn & Associates

BJC North Garage Expansion

BJC Hospital in St. Louis was out of parking spaces on their ever expanding campus, and one solution was to expand the North Garage built by KCI in 2001. The new garage was built on drilled piers, with the new entry ramp and three parking levels being constructed of cast-in-place, post-tensioned concrete. Precast panels were salvaged from the original garage and reinstalled on the new facade. Additional spaces were opened in the existing garage with completion of an adjacent asphalt surface lot for valet services. Construction was completed in eleven months, while working in the middle of a busy hospital campus and rerouting traffic within the garage during construction.

"On top of the everyday challenges of new construction, expansion of existing parking structures present many additional and unique challenges. KCI's professionalism and attention to quality and detail resulted in the on time and within budget completion of a very challenging project."
Dave Ryan, Walker Parking Consultants

Vitals

180 cars
4 levels

BJC St. Louis

General Contractor

$5,180,000

Bid Build

January 2006

Walker Parking Consultants

CBRN Response Training Facility

The CBRN Response Training Facility occupies approximately 40 acres and provides an unmatched state-of-the-art training facility for all authorized response agencies. The US Army Chemical School is the Department of Defense lead for Joint CBRN Response Training. The project involved multiple buildings in a town setting, with construction varying between structural stud frame with masonry & insulated panel veneer, and pre-engineered structures. Portions of the project were awarded via the design-build method, with KCI and Black & Veatch teaming. Buildings provide classrooms, office space, labs, after-action review rooms, and decontamination training bays. Underground tunnels connect the buildings of the Urban Training Area, and replicate a cave complex to support enclosed space, clandestine laboratory, and chemical/biological munitions cache training scenarios.

Vitals

65,000 square feet
on 40 acres

U.S. Army Corps of Engineers

General Contractor

$14,375,000

Bid Build

August 2007

Black & Veatch

MAE Addition & Renovation

The renovation and expansion of the Mechanical and Aerospace Engineering complex was renamed Toomey Hall upon completion, based on the lead $5 million gift from John and Mary Toomey. The modernization renovated the existing 66,500 square foot building, and replaced the outdated Mechanical Engineering Annex - built in 1902 - with a modern addition. The new three-story steel framed addition of 80,500 sf was built next to the existing building which remained in service, and then upon completion the classes were moved into the new space to allow for renovation of the existing building. A three-story atrium connects the two buildings and houses the Product Innovation and Creativity Center.

"We found KCI to be extremely reliable and responsible throughout this very complex project. KCI continually demonstrated professionalism, high standards of construction work ethics and a sincerer dedication to high performance standards throughout the project. The University would highly recommend this firm for any type of new construction, rehabilitation or renovation project."
Ted Ruth - Missouri University of Science & Technology

Vitals

147,000 SF

Missouri University of Science & Technology

General Contractor

$26,090,000

Bid Build

July 2009

Cannon Design

Animals Always Sculpture

The Animals Always Sculpture Plaza serves as an icon for the St. Louis Zoo and as a gateway to the south entrance to Forest Park. KCI was selected for construction of the concrete foundations, site development and erection of a $1 million, 25-piece, Core-Ten steel sculpture created by artist Albert Paley. The project involved numerous challenges including working near a busy intersection of pedestrian and vehicular traffic. KCI utilized our in-house layout services to accurately place an extensive configuration of hundreds of anchor bolts, which needed to be correct in order to set the intricate sculpture in place.

2007 Regional Excellence Award - St. Louis Construction News & Real Estate

Vitals

25-piece Sculpture

St. Louis Zoo

General Contractor

$600,000

Bid Build

June 2006

HNTB Corporation

Southwest Bank O'Fallon

Southwest Bank chose to build a branch bank in the rapidly expanding O'Fallon, Missouri area, and selected KCI as Construction Manager for the project due to our longstanding relationship with the Bank. The branch bank consisted of a concrete basement to house unsightly HVAC units, a precast plank floor, and metal stud with masonry veneer construction. All work was completed within a tight schedule, allowing the owner to open on schedule and begin banking in their newest market area.

Vitals

10,000 SF

Southwest Bank

Construction Manager

$2,190,000

Negotiated

April 2007

Dawdy & Associates

Schweitzer Hall Addition

Historic Schweitzer Hall is key to the University of Missouri fulfilling the campus and system commitment to research, instruction and external funding in the area of Medical and Life Sciences. This project allowed critically needed laboratory spaces near clinics to be vacated, and through consolidation of the Biochemistry faculty, enhanced the productivity of the notably successful UMC Department of Biochemistry. The building addition included a bridge to the original building and was constructed of a structural steel frame with limestone veneer and slate roof to match the existing building. Additionally, underpinning of the existing building was required to install the new basement, which needed fiberglass reinforcing to accommodate a Nuclear Magnetic Resonance spectrometer that serves the entire University of Missouri System and was the first in the State of Missouri. Two stories and a mechanical penthouse above the NMR basement floor, house state-of-the-art laboratory spaces and department offices.

Vitals

22,000 SF

University of Missouri - Columbia

General Contractor

$7,400,000

Bid Build

October 2007

GLPM Architects

Brady Commons Addition

This addition to the existing student center was the first phase of the complete renovation of the existing facility, and included selective demolition, site improvements and the addition of a new four-level concrete structure. To facilitate construction, we were required to provide shoring to support the existing and fully occupied two level building, which was just five feet from the new structure. The schedule was maintained despite numerous owner initiated changes to ensure the building was complete by the Christmas Break, so that the owner could maintain revenue levels for the bookstore that exceed $100 million annually.

Vitals

100,000 SF

University of Missouri - Columbia

General Contractor

$19,730,000

Bid Build

December 2008

Mackey Mitchell

Lafferre Hall Addition

Lafferre Hall is home to the College of Engineering on the University of Missouri Campus, and when built in 1892 was one of the first Engineering schools west of the Mississippi River. The building received additions in 1922 and 1935 and again in 2007, when KCI was selected for this project. The project includes renovation of 25,000 square feet of existing space and 60,000 square foot addition in a three-story concrete-framed building. The pan deck frame received structural stud and brick/stone veneer to match the original building and subsequent additions. When construction began in 2007, initial excavations revealed an underground "river" of groundwater as well as lack of foundations under the original building. These challenges were addressed and the project completed to include general classroom and laboratory space.

Vitals

85,000 SF

University of Missouri - Columbia

General Contractor

$17,515,000

Bid Build

August 2009

The Clark Enerson Partners

Carondelet Recreation Complex

Certified as a LEED Silver project, the Carondelet Recreation Complex is a full service recreational facility, enjoying meeting room, classroom, fitness, natatorium and gymnasium spaces. The facility also includes an exterior plunge pool, lazy river and tot pool facilities which include several play devices for preschool and grade school children. Athletic endeavors are rounded out with a softball field in near proximity, and the entire complex is situated within a local city park. Facilities are on two levels allowing for substantial indoor running track capability. The original pricing was substantially over the owner's budget which allowed a joint value-engineering effort. KCI worked with the owner and architect KAI Design Build, to achieve substantial savings while maintaining the facility mission and LEED accreditation.

Vitals

72,000 SF

City of St. Louis

General Contractor

$21,090,000

Bid Build

November 2010

KAI

Lutheran Church of the Resurrection

As design was nearing completion, KCI was selected as the Construction Manager at Risk for this project, in an effort to expedite the start of construction. The church was growing beyond capacity of its current facility, and this project expanded the building in almost every direction. A two story, 3,000 square foot concrete framed addition was built onto the southwest corner to house office and classroom space. The multi-purpose gymnasium was opened to the north by adding a 2,000 square foot stage and storage area. A new office for the early childhood center was added to the northeast corner. To bring everything together, a new entrance was built on the south face, with interior renovations to the main lobby/gathering area, restrooms and lower level daycare areas.

Vitals

10,000 SF

Lutheran Church of the Resurrection

Construction Manager at Risk

$2,900,000

Negotiated

July 2010

Stauder & Associates

Greystone Condominium Exterior Improvements

On a 15-story, 1920's circa building, the original concrete balconies had deteriorated to a point that they were unsafe for use. Initial evaluation of the decks indicated less than 5% spalling of the balconies, but upon demolition it was discovered that some decks had over 50% deteriorated concrete. Thus, the levels were replaced one at a time to accommodate safety concerns and forming systems, and to allow owner use of remaining balconies in summer months that construction took place. All new balconies were architecturally stamped, stained and sealed and provided with new architectural painted handrails, and the underside of the new concrete sealed with an elastomeric sealer.

Vitals

14 stories

Greystone Condominium Association

General Contractor

$1,100,000

Bid Build

October 2010

OWH

Sunvilla Tower Renovation

Sunvilla Tower was built in 1963 as an 18-story high-rise luxury apartment building, and remained the tallest in Springfield until 1987. In 1976 Missouri State acquired the property and 2 acres of land, and had performed various renovations and improvements over the years. This latest renovation will install fire suppression system throughout the building, allowing them to place the apartment kitchens back in service. Additional renovations include aesthetic enhancements with new doors and painting, as well as exterior sealing/tuckpointing, and mechanical & electrical upgrades.

Vitals

125,000 SF

Missouri State University

General Contractor

$10,939,000

Bid Build

August 2015

The Lawrence Group

Loop Trolley Transportation Building

The project consists of Renovation and historic restoration of the building at 5875-5893 Delmar Boulevard in St. Louis. The completed work will provide the owner with a renovated building modified for the Loop Trolley Maintenance & Storage Facility and first floor office space. Work includes historic renovation of the southern facade, complete demolition of interior components, underpinning existing brick walls, and installation of new recessed trolley car maintenance bays, to facilitate the trolley system being installed by KCI Construction under separate contract.

Vitals

26,000 SF

Loop Trolley Transportation Development District

General Contractor

$8,909,000

Bid Build

May 2016

CH2M Hill

Tactical Equipment Maintenance Facility

Site preparation on the 50 acre site included substantial timber clearing and over 40 foot of fill work, and in spite of the earthwork being accomplished over the winter months, progress has continued to allow for an anticipated delivery as scheduled in April of 2014.

The Tactical Equipment Maintenance Facilities (TEMF) will provide LEED Silver facilities for the maintenance and repair of various operational vehicles which also includes equipment storage, parts storage and administration space. The complex includes seven separate buildings that are a combination of pre-engineered metal buildings, load bearing masonry and steel framing.

Site development includes construction of new asphalt & concrete streets, miles of sanitary sewer and water services, Bio-containment structures and a 5 acre lined retention pond complete with wet land plantings. 13" thick concrete hardstand area includes approximately 600,000 SF of paved area and 315,000 sf of asphalt.

Vitals

55,000 SF

Army Corps of Engineers

General Contractor

$31,730,000

Bid Build

April 2014

Army Corps of Engineers

BCT-3 South Phase 2 Dining Facility (DFAC)

In recent years the Federal Government has followed a trend of setting aside construction projects for small, disadvantaged, minority or veteran owned businesses. KCI Construction does not fit those classifications, and as a result teams with a business that does fit the classification. This was the first successful teaming arrangement, as KCI and Donald Maggi were awarded this small-business set-aside summer of 2013. Upgrades and realignment at the Ft. Leonard Wood Army Base necessitated this facility, for dining by 1,300 soldiers stationed in the new BCT-3 South Barracks. The single story building is simple construction of concrete foundations, steel frame, masonry veneer and standing seam roofing.

Vitals

29,771 SF

Army Corps of Engineers

General Contractor

$5,670,000

Bid Build

December 2014

Clark Nexsen Architecture & Engineering

Valicor Waste Liquid Processing Facility

Valicor Environmental Services is dedicated to be the leader in waste minimization/waste management, and operates facilities in Ohio, West Virginia and Alabama to receive waste liquids and then treat and separate them into usable liquids for resale. St. Louis is a new territory for Valicor, and KCI is pleased to have been selected for their contractor in this market. Work is proceeding on conversion of a 56,000 sf warehouse in north St. Louis, to be able to accept and process waste liquid within a three month construction window. Our scope includes the addition of overhead roll-up doors, ramps to allow tanker trucks to back into the building, and installation of Valicor-furnished tanks and separation systems, as well as process piping, electrical and control work.

Vitals

56,000 SF

Valicor Environmental Services

General Contractor

$600,000

Negotiated

December 2013

Cornerstone Architecture

Regional Training Institute Phase 1

Currently the Missouri National Guard's 140th Regiment Training Institute complex does not meet the Training and Doctrine Command (TRADOC) accreditation standards, and this new facility is being constructed to provide the latest in a modern training environment for Engineers, Military Police and Chemical MOS's. The two story building is situated on a twelve acre site, with two thirds of the building laid out in a radius format, making layout and construction a greater challenge than a linear building. The building will house training spaces, auditoriums, classrooms, and offices with polished and dyed concrete floors and terrazzo floor finishes.

Vitals

55,000 SF

Missouri Army National Guard

General Contractor

$14,906,000

Bid Build

January 2015

Jacobs

Virginia Avenue South Student Housing

After ten years of record-breaking enrollment and a consequent increased demand for on-campus housing, Mizzou approved plans for a new 330 bed dormitory, just south of the Virginia Avenue Housing and Dining Complex. KCI was the successful bidder on this 5-story community-style hall, which includes 20 percent single rooms and 80 percent double rooms. Construction is challenged by the installation of a new steam manhole and chase nestled between, over and under existing utilities within a confined area of the site. The project will utilize a dovetailed metal floor deck as the exposed finish ceiling on thousands of square feet of common area and dorm rooms. This decking requires shoring to facilitate concrete placement and until the floor has gained design strength to span the open spaces on the project.

Vitals

93,000 SF

University of Missouri - Columbia

General Contractor

$20,483,000

Bid Build

February 2015

Treanor

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 KCI built on our campus has exceeded our expectations aesthetically and functionally."
Blanche Touhill, Chancellor, University of Missouri - St. Louis

Vitals

670 cars
4 levels

University of Missouri - St. Louis

General Contractor

$9,080,000

Design Build

May 1999

Tom Brooks-Pilling / SSE

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.

Vitals

100,000 SF

Harwood & Associates

General Contractor

$18,350,000

Design Build

November 2003

Cannon Design

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 accommodate student relations, and only one entrance to the site which was along a main pedestrian and vehicle thoroughfare on campus, maintaining a tight schedule was a challenge. However, KCI and IAA worked through all challenges with the owner, and turned over two of the four buildings ahead of schedule.

Vitals

270,000 SF

University of Missouri - Columbia

General Contractor

$46,800,000

Design Build

August 2009

International Architects Atlier

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 bollards and cable gates. Upon project completion, KCI received the highest rating possible from the USACE.

Vitals

162,000 SF

U.S. Army Corps of Engineers

General Contractor

$24,300,000

Design Build

December 2011

International Architects Atlier

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 in a two year span with no OSHA violations.

"As the region's second design-build highway project through an environmentally sensitive corridor, the Page Olive Connector presented a unique set of challenges in all areas of the project. From day one, KCI met these challenges, head on, by continually developing and implementing innovative solutions."
Matt Grundler, Project Manager, St. Louis County

Vitals

2 miles

St. Louis County

General Contractor

$52,500,000

Design Build

July 2012

Jacobs

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 into modern, state of the art facilities at the St. Louis County Court Complex located in the City of Clayton. The scope of the project includes a goal of LEED Silver Certification; renovations to the four-story parking garage under the building; improved public wayfinding and circulation; upgrades to mechanical, electrical and security systems; new elevators; and a complete revamping of the security configuration and redesign of the jury assembly rooms.

Vitals

380,000 SF

St. Louis County

General Contractor

$122,000,000

Design Build

August 2016

Fentress Architects

Lower Meramec Lift Station

It isn't uncommon the 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 their great team effort, and take pride in working with them on this challenging project."
Marie Collins, Assistant Director of Engineering, MSD

2007 AGC Keystone Award - Project of the Year

Vitals

200 feet deep

Metropolitan St. Louis Sewer District

General Contractor

$32,570,000

Bid Build

March 2007

Horner & Shifrin

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 of the Pump Stations."
Mike Yerion, Project Manager - City of St. Peters

Vitals

2 pump stations

City of St. Peters

General Contractor

$5,400,000

Bid Build

December 2006

Jacobs

Marshall Road Pumping Station

When the City of Kirkwood entered into an agreement with Missouri American Water Company to purchase water from MAWC instead of treating it themselves, the Marshall Road Treatment Facility was no longer needed. KCI took on the challenge in Fall 2006 to convert this facility to a pump station to supply water to Kirkwood residents in time for the Spring 2007 demand. Working closely with a knowledgeable and motivated owner, KCI was able to overcome numerous obstacles and develop another satisfied customer. The project scope included demolition of all structures except the main building, which was gutted of interior piping systems. New pumps, piping, electrical and controls were installed, and wells along the Meramec River abandoned.

"I have not worked with a better general contractor in my 30-year career."
Tim Rajchart - Water Department Director, City of Kirkwood

Vitals

1 Pump Station

City of Kirkwood

General Contractor

$1,750,000

Bid Build

May 2007

CH2M Hill

Grand Glaize Wastewater Treatment Plant Expansion

The existing MSD Grand Glaize WWTP had become undersized due to local developments and required an increase in capacity from 16 million gallons per day (MGD) to 21 MGD. KCI was awarded this publicly bid project, which consisted of replacement of coarse and fine screens, addition of a screening washer and compactor, construction of four primary and two final clarifiers, a primary sludge pump station, two concrete aeration basins, a blower building and return sludge pump station. Additionally the project included modifications to three existing aeration basins and four final clarifiers, and the addition of an odor control system. This work was accomplished through close coordination with the existing plant to achieve nine intermediate project completion milestone dates, so that the new and existing plants could be integrated. This integration also included the challenge of numerous tie-ins to live piping systems, while working with aging diversion gates that didn't necessarily divert all of the flow they were supposed to.

Vitals

21 Million Gallons per Day

Metropolitan St. Louis Sewer District

General Contractor

$28,900,000

Bid Build

December 2008

HDR Engineering

O'Fallon Biofilter Complex Improvements

Between the fall and winter of 2006 three of the four screw pumps that convey wastewater to the bio-towers at the City of O'Fallon's treatment plant become inoperable. Upon inspection it was determined that repairing the pumps was not feasible. Since bypassing the pumps was a violation of wastewater permits, the City required an emergency procedure to replace the pumps. Due to the relationship between the City and KCI, we were selected for these emergency pump replacements. Working closely together with the City and the design team, initial planning to final construction was completed within 4.5 months and under budget, and the plant experienced no permit violations.

Vitals

3 Pumps

City of O'Fallon, MO

General Contractor

$1,075,000

Negotiated

October 2007

Donohue & Associates

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 inside the 1,300 foot long Corrective Additives Building. These two foundations were built to support rail guide equipment that ran the length of the building, with one foundation being 26 feet wide and the other 18 feet wide. Excavation to top of rock supporting the foundations ranged from one to thirty-five feet deep, and KCI placed over 4,500 cubic yards concrete and installed over 360 tons of rebar.

Vitals

23,500 CY concrete
1,750 tons rebar

Holcim

General Contractor

$11,900,000

Bid Build

March 2008

CH2M Hill

Spencer Creek Solids Processing Facility

Prior to this project, wastewater sludge for the City was stored in lagoons and then applied to farm ground when weather conditions were favorable. This project allowed them to greatly reduce the sludge odors from the lagoons, and convert sludge to a cake product that was mixed with yard waste to create a Class A compost, allowing management of the organic waste stream to provide 100% beneficial reuse of the materials into sale to public and private contractors. KCI constructed a dewatering building to house two belt presses, converted two sludge holding tanks to fine bubble air diffuser systems, and installed 1,100 linear feet of gravity sewer and 2,100 linear feet of sludge force mains.

Vitals

5,100 square feet

City of St. Peters, MO

General Contractor

$4,125,000

Bid Build

December 2008

CDM

Fabric Tank Replacement

Two 500,000 gallon fabric tanks (fabric reinforced rubber bladders contained within earthen berms) had far exceeded their 20-year life expectancy, and that coupled with City growth necessitated additional water capacity. KCI and tank subcontractor Preload built the 95' diameter, 40' tall tank on a 22" thick concrete base slab supported on 176 sixty-foot long H-piles driven to bedrock. Tank wall panels were precast on site, with integral steel diaphragms to provide water tightness. A wooden shoring and forming system was built to place the cast-in-place domed roof, and then the tank was wound with steel wire and coated with shotcrete and a maintenance free coating.

Vitals

2.1 million gallons

City of St. Peters, MO

General Contractor

$2,440,000

Bid Build

August 2008

Black & Veatch

Creve Couer 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 Couer 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 station then built with 5'-0" thick footing slabs and walls. Additionally, project scope included over 1,000 linear feet of influent force main and discharge piping, ranging in size from 30" ductile iron pipe to 72" reinforced concrete pipe. The pump station houses five 15 MGD pumps, a biofilter system, screening and channel grinders, and an emergency generator.

Vitals

60 MGD
40 feet below grade

Metropolitan St. Louis Sewer District

General Contractor

$19,930,000

Bid Build

June 2010

CDM

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" sludge system that virtually eliminates the need to dispose of sludge byproduct, which is a costly ongoing expense for many plants. The new plant consists of an influent pump station, Administration & Headworks building, 4-cell VLR, two 90' diameter Clarifiers, Sludge Pump Station, UV Structure, and Effluent Pump Station. Piping connects the new plant to the existing plant via a 48" diameter boring under the high-speed railroad.

"We have nothing but good things to say about the general contractor"
Brian Boehmer - Assistant City Administrator, City of Washington

Vitals

6 Million Gallons per Day

City of Washington, MO

General Contractor

$19,840,000

Bid Build

October 2009

Jacobs

O'Fallon UV System Replacement

When the City of O'Fallon's UV System failed during disinfection season, the City staff selected KCI Construction and Donohue & Associates to design and construct a replacement disinfection system for its wastewater treatment facility on an emergency fast-track schedule. Within six months following the failure of the existing system, the new project was designed, constructed, and put in operation in time for the subsequent disinfection season. The project includes a new 70 foot long concrete channel and dual in-channel UV disinfection units, with flow diversion structures and gates, canopy over the structure, and new controls and exterior lighting.

Vitals

2,500 square feet

City of O'Fallon, MO

General Contractor

$1,100,000

Negotiated

December 2008

Donohue & Associates

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 replacements were taking place over a 19 month schedule, five phases of electrical upgrades included MCC replacements and installation of 13.8kV switchgear. During all work, the power plant and ancillary services were required to remain in operation, making owner coordination a necessity on a weekly, daily, and sometimes hourly basis.

Vitals

18,000 SF

University of Missouri - Columbia

General Contractor

$14,990,000

Bid Build

June 2010

Jacobs

O'Fallon Sludge Blend Tank Rehabilitation

The owner had a sludge blend tank that was not in operation due to equipment failures and concerns about extensive corrosion on the concrete walls of the tank. It was critical for the city to get the tank back in service to resume sludge processing operations. Because of this a short bid period was followed by a 70-calendar day project duration from notice-to-proceed to having the tank operational. Work during this short project duration included epoxy glazing a corrosion barrier liner on inside of the tank walls, new sludge mixing pumps and nozzles, foam buster pump and nozzles and a new tank aeration system. Additionally, new exterior aluminum access stairs were installed, along with miscellaneous mechanical, electrical and controls upgrades.

Vitals

70 foot diameter

City of St. Peters, MO

General Contractor

$470,000

Bid Build

October 2009

Donohue & Associates

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 Grit Facility, Dewatering and Blower Building, and renovation of existing Clarifiers, Aeration Basins and Influent Pump Station & Screening Facility.

Vitals

26 Million Gallons per Day

City of Columbia, MO

General Contractor

$55,590,000

Bid Build

September 2013

Black & Veatch

O'Fallon Water Plant Filter #5 Installation

The original project scope called for installation of a fifth water filter inside the existing water plant treatment building, and then removing Filter #1 from service to retrofit it with new filter media and internal mechanisms. The installation of the owner-furnished Filter #5 was completed and then placed in service as planned. Upon removal of Filter #1 from service, a hole was discovered in the bottom of the tank, and our work was placed on hold for over a year, while the City and Filter manufacturer discussed responsibility and solutions. Ultimately a corrective solution was determined, and KCI resumed work, completing the work a few months later.

Vitals

2 Filters

City of O'Fallon, MO

May 2012

$679,000

Bid Build

May 2012

Woodard & Curren

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 of the leakage points and installed 2,100 linear feet of HDPE pipe underground to a new collection basin. This piping was routed under a 15 foot wide plant road with fence on one side and cliff drop off on the other, making logistics and safety paramount. Approximately 1,000 linear feet of 24" diameter steel pipe was then routed from the basin, up the side of the reservoir, and across the dam allowing collected water to be pumped back into the reservoir. All of this work was accomplished in a tight three-month time frame to allow Ameren to meet a Federal Regulation deadline.

Vitals

3,100 lf Piping

Ameren

General Contractor

$730,000

Bid Build

September 2012

Ameren

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 Facility consists of five channels of 20 modules of 36 UV lamps, which treat the wastewater prior to an average daily discharge of 167 million gallons into the nearby Mississippi River.

Vitals

25,200 square feet

Metropolitan St. Louis Sewer District

General Contractor

$21,700,000

Bid Build

September 2013

HDR

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 of the old sewer. After that the river level rose and shut down construction for months, and upon re-starting work KCI worked overtime to beat the upcoming river level rise, and should complete the work substantially ahead of the contract completion date.

Vitals

120 linear feet

Metropolitan St. Louis Sewer District

General Contractor

$2,400,000

Bid Build

October 2013

KDG, Inc.

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 Administration Building. The new plant also includes approximately 9,000 feet of 42-inch to 60-inch diameter influent and effluent sewer lines, and upon completion the existing plant will be decommissioned by KCI.

Vitals

Peak Capacity 50 MGD

City of Cape Girardeau, MO

General Contractor

$55,500,000

Bid Build

August 2014

Jacobs

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 Road and one creek, all of which posed unique challenges and coordination issues. KCI also built the new Shrewsbury passenger station and park-and-ride surface lot. In total, construction included 25,500 linear feet of steel support piling, 1,900 tons of reinforcing steel and 24,300 cubic yards of concrete.

Vitals

1.3 miles

Metro

General Contractor

$38,900,000

Bid Build

April 2006

Cross County Collaborative

Kingshighway Viaduct

As part of an overall streamlining of the intersection of Kingshighway and Interstate 70 in north St. Louis that was performed by MoDOT under separate contract, the City of St. Louis opted to replace a deteriorating bridge over existing Terminal Railroad tracks in the area. KCI was responsible for h-pile foundation supports, concrete walls and abutments, installation of the conspan precast bridge segments spanning the tracks, and installation of the precast stone caps and exposed aggregate handrail. Once the new bridge was completed and paving installed as part of a road straightening project to eliminate a dangerous intersection, the existing Kingshighway bridge was demolished under separate contract. All of this was achieved through close coordination with the railroad and other contractors working in the area of the Interstate 70 interchange.

Vitals

Single Span

City of St. Louis

General Contractor

$2,250,000

Bid Build

July 2005

Jacobs

Chouteau Avenue Bridge

The existing Chouteau Avenue Bridge in St. Louis City was originally constructed in 1890, and because of its severely deteriorated condition only two of the five original lanes were being used in 2005. This project included closing the bridge so that complete demolition could occur over the seven active Union Pacific and Burlington Northern rail lines underneath. The bridge was replaced with two steel girder bridges spanning between three MSE walls, and encountered contaminated water underground due to years of chemical spills in the area. In addition, the Vandevanter overpass bridge/ramp was replaced, so that the ramp from eastbound I-64 ends at Vandevanter rather than the Chouteau Avenue overpass.

Vitals

Two single spans

Missouri Department of Transportation

General Contractor

$12,420,000

Bid Build

December 2006

URS

I-64 Seismic Retrofit

In an effort to make an elevated section of I-64 in downtown St. Louis remain standing during an earthquake, MoDOT awarded the second to last phase of this project to KCI, which was the second for KCI. This package included seismic upgrades on the section of highway from 7th to 11th Streets, and painting of all structural steel from 7th to 14th Street. This congested area of downtown St. Louis required us to coordinate working in the parking lot of the General Services Administration, alongside and above Metrolink light rail tracks, above City streets, and next to Busch Stadium. Constant communication with these factions, as well as dealing with traffic on the highway and streets below, made this project an example of coordination. The project scope included 1.3 million pounds of structural steel, 130,000 pounds of steel column collars, and 144 drilled piers ranging in depths from 30 to 75 feet.

Vitals

0.3 miles

Missouri Department of Transportation

General Contractor

$28,275,000

Bid Build

March 2012

Jacobs

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 in a two year span with no OSHA violations.

"As the region's second design-build highway project through an environmentally sensitive corridor, the Page Olive Connector presented a unique set of challenges in all areas of the project. From day one, KCI met these challenges, head on, by continually developing and implementing innovative solutions."
Matt Grundler, Project Manager, St. Louis County

Vitals

2 miles

St. Louis County

General Contractor

$52,500,000

Design Build

July 2012

Jacobs

Park Over the Highway

CityArchRiver 2015 has a goal of uniting our region and one of the world's most recognizable icons with another of our greatest assets - the Mississippi River-we will build new connections, invigorate existing attractions and expand points of interest beyond the existing park to the East and West riverbanks and into the region itself. The design starts with a new, dramatic Park Over the Highway that will, for the first time, allow 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. This Park Over the Highway will be possible by the award to KCI of the first project of many in sequence. The project scope includes rerouting of traffic at the Eads Bridge and Washington Avenue and a new exit from I-55 North/I-70 West onto the Landing, followed by a 90-day replacement of Walnut Street overpass at the south end of the project, and demolition of the Market and Chestnut overpasses and installation of a new block-long land-bridge. This land bridge will be the eventual home to the Park Over The Highway.

Vitals

2 Bridges

Missouri Department of Transportation

General Contractor

$26,430,000

Bid Build

June 2015

MoDOT

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.

Vitals

2.2 miles

Loop Trolley Transportation Development District

General Contractor

$22,575,000

Bid Build

May 2016

CH2M Hill