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Weidmann Electrical Technology Manufacturing Expansion

 

Weidmann Electrical Technology, a producer of electrical transformer insulation material, initiated a 38,000 sf expansion (65 ft by 283 ft by 60 ft high) to house a new 2,000,000-lb hot press for increased production capacity at their St. Johnsbury facility. Building construction and equipment investment totaled $38M. To meet client schedule goals, the project was fast-tracked and delivered through a construction-managed process.

D&K provided conceptual, preliminary, and final design services, as well as bid/negotiation assistance and construction phase services related to the design and construction of the foundation and structural systems. D&K also provided Special Inspection coordinator services during the construction of the project.

Problematic soil conditions required the use of a complex foundation system consisting of 48-inch and 60-inch diameter caissons, grade beams, and a 500-pound per sf capacity structural slab on grade. The superstructure consisted of structural steel framing, an elevated floor with 500-psf load capacity, and a 30-ton overhead bridge crane.

The structural and foundation design were developed by integrating the use of RAM Structural System with AutoDesk’s Revit Structural System for 3-D modeling and construction document production.

The project received a Grand Award in the Engineering Excellence Awards sponsored by the American Council of Engineering Companies/Vermont Section. The project was recognized as an outstanding example of engineering excellence in the category of: Buildings, Structures, and Support Systems.

Water Tank and System Upgrades

 

DuBois & King repackaged construction documents and provided redesign, cost estimating, bidding assistance, and construction phase services for drinking water supply and storage improvements, as well as minor access road improvements in the Town of Proctor. D&K staff separated one construction contract into two, and repackaged contracts to incorporate cost-saving features as a means to reduce overall construction costs to the Town. D&K assisted in bringing projects within budget and brought the water system back into compliance with State and Federal requirements, including longstanding violations involving Disinfection Byproducts (DBPs):

Replacement of the East Side Water Storage Tank
Tower Road improvements
Replacement of an isolation valve/improvements to the West Tank

Water Storage Tank Design

 

Preliminary engineering study, final design, and bid and construction services for this major improvement to the Williamstown water system. The project included construction of a single chamber, pretensioned, precast concrete, circular 675,000-gallon storage tank, draining and removal of existing reservoirs from service, interconnecting piping to utilize existing well pumps, and connection to existing distribution system. New storage tank was sited to boost water pressure to the upper portion of the distribution system, including the high school. To avoid excessive pressures in the lower portion of the distribution system, two pressure zones were created using strategically located pressure reducing valve stations.

Services included topographic survey, subsurface exploration, final design and specifications, hydraulic modeling of the distribution system, permitting, cost estimating, bid phase and construction phase services, and project meetings. Special services include documentation to the Water Supply Division and applications for State Revolving Funds.

Water Storage Tank and Utility Extensions

 

In an effort to increase the volume of domestic and fire protection water storage for the Town, D&K provided design services to replace two 80-year-old riveted steel tanks with a new 833,000-gallon glass-fused-to-steel water storage tank. The project included staged demolition of existing tanks due to tight site conditions and required maintaining storage from one existing tank during construction of the new tank.

D&K staff coordinated internal well video inspection during design to evaluate the integrity of the existing well screen. Well improvements were necessary to maintain pumping capacity at new discharge conditions associated with taller water storage tank, including replacement of pump bowl assembly, reduced voltage starter, new telemetry system, and other electrical improvements.

Replacement of 2,900 lf of water main and 800 lf of sewer main was necessary to comply with regulations regarding separation distance between water/sewer lines and to improve hydraulic capacity. D&K staff prepared bond vote informational flier and application for State Revolving Loan Funds.

Wastewater Treatment Upgrade

 

Comprehensive upgrade of 40-year-old wastewater treatment facility and process conversion from tricking filter to sequencing batch reactor (SBR) to comply with stringent phosphorous limitations. Replaced outdated headworks with fine screen and aerated grit chamber to improve removal of inorganics and FOG. Project included an innovative reuse of existing treatment process tank for post-SBR flow equalization, resulting in $200,000 savings.

Completed upgrade/replacement of biosolids processing including replacement of anaerobic digesters with aerated sludge storage, evaluation of alternative sludge dewatering technologies, new centrifuge and dewatered sludge screw conveyor, and efficient on-site storage/off-site hauling. Eliminated public health/safety threat by converting from 1-ton gas chlorine to liquid chlorination/dechlorination system. Energy efficient design techniques included premium efficient motors, heat recovery system from blower room, innovative day-lighting in Control Building, and new SCADA system for improved on-site/off-site monitoring. The site was constrained by the railroad and the Dog River, requiring geotechnical measures to protect rails.

DuBois & King was the prime consultant and provided all the professional engineering services associated with this facility, including structural, civil, electrical, mechanical, and construction inspection and management. The project received an award for engineering excellence in the annual competition sponsored by the American Council of Engineering Companies, Vermont Section.

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