"PROMISES MADE, COMMITMENTS KEPT"
Below are a few recent projects that KE&G would like to share. Please check back often to view our newest projects.
CITY OF DOUGLAS WASTEWATER GRAVITY COLLECTION SYSTEM FOR BAY ACRES
The Wastewater Gravity Collection System located in Bay Acres was a multiple-step project to upgrade an existing subdivision from septic tanks to mainline sewer connections. This project consisted of approximately 3,900 linear feet of 12-inch pipe and an additional 22,300 linear feet of 8-inch PVC sewer main under the streets. KE&G installed over 470 HCS connections from the mainline to the property line, which added up to over 50,000 linear feet of 4-inch house lines. Each connection was then installed on properties where people currently lived, which made for tight working conditions. Every house had a septic tank and KE&G was required to demolish then filled the tanks with sand or dirt. There were several unique septic tank locations that were discovered. In 2 cases the septic tanks were under the homes living room. These tanks were successfully filled with a concrete slurry due to limited access. KE& was able to successfully communicate the importance of safety with all the homeowners and mitigate all potential hazards by the use of steel plates, orange fencing, barricades, and daily communications with homeowners. This was a successful project for KE&G and an added asset to the City of Douglas and Cochise County.
SOUTH RILLITO INTERCEPTOR REHABILITATION
Rehabilitation of approximately 3.2 miles of 48-inch and 54-inch sewer interceptor line. The work involved slip-lining and cured in place pipe (CIPP) along 3.2 miles of the major sewer interceptor. This work also included the installation of 1,054 linear feet of 48-inch CIPP; 10,409 linear feet of 54-inch CIPP; 3,841 linear feet of 44-inch slip-lining; 1,301 linear feet of 48-inch slip-lining; 3 major sewer bypasses that pump 16 million gallons of sewage daily; 12 minor sewer bypasses; 10 manhole reconstructions, 37 manhole rehabilitations, site work concrete, and numerous pavement patches.
Major Risk Items Identified and Solutions Offered/Utilized: The existing Southeast Interceptor Sewer was located directly below Davidson Elementary School. KE&G worked with Pima County along with TUSD to schedule the CIPP around school hours and targeted the summer months to complete the installation. Also, when bypassing a large interceptor, costs can add up quickly. As the CMAR, our CIPP bid packages contained an incentive for early completion. Approximately 25% of the savings would go back to the Subcontractor, and RWRD would receive the balance. This incentive proved beneficial, as the CIPP subcontractor worked around the clock for 28 continuous days to finish early a the 18 calendar day mark. As the final CIPP rehabilitation GMP was progressing, KE&G worked with Westland Resources to assess the feasibility of completing the 3rd phase of the project with slip lining, which would require significantly less bypass pumping. Upon acceptance by RWRD, KE&G was able to return over 1 million dollars to RWRD as project savings by slip lining instead of CIPP rehabilitation for phase 3.
Value-added Options or Differentiators: The routing of the bypass piping affected the Rillito Walking Path was a path used by The Humane Society dog-walking volunteers. Upon increased traffic through the construction zone by volunteers, KE&G and RWRD met with the group to come up with an action plan. KE&G then negotiated with a local subcontractor whose property was directly adjacent to the Humane Society. KE&G then provided a dedicated walking path through the private property which provided safe access from construction activities.
This project was to bring the existing private property site drainage way up to regulation standards. The scope included replacing existing drainage channel with the larger concrete-lined channel, relocating the existing haul road, adding two new culvert crossings of 6 EA 72″ CMP culverts, constructing a new concrete inlet structure, new riprap outflow, and re-pave existing asphalt access road. This project was to be delivered in an abbreviated schedule window with an accelerated start date. Challenges included rock excavation, maintaining the ongoing owner heavy equipment haul roads and traffic, and maintaining a tight schedule. The final contract amount for this project was $1,499,776.
BENSON AIRPLANE BARNS
This project consisted of clearing and grubbing the site, subgrade prep which was minimal due to the site being relatively flat. There was a total of 44 column footings that required over excavation with a 5ft blow out on each side. This was completed using a backhoe and wackers. The slab was constructed of 5” thick reinforced concrete that was poured in sections to accurately achieve the required .5% slope. Each of the 44 columns had four anchor bolts that were meticulously surveyed to ensure complete accuracy. The prefabricated building was then erected by Weather Guard under the supervision of KE&G. During the time of the building installation cement-treated base was installed under the areas to be paved to allow for a hard subgrade. Once the building reached, 30% completion the electricians and fire suppression installers were brought in to run the conduit to all of the 12 individual bays as well as the fire riser room and pilots’ room. The building framing was completed in early January 2019. This allowed KE&G to pave the sloped entrances to each bay. This area is crucial and the slope had to be low enough to allow easy movement of aircraft in each bay as well as allow shed water to the main drainage ways. Once paved the final items were completed with inspections ensuring operations of all systems and tying into the main power feed with SSVEC. The main challenges on this project were the slow response to questions, as well as getting the electrical and fire suppression systems set up with the City Of Benson and SSVEC. Overall, this was a great project because this was a unique Design, Bid, Build project in a rural area and on an airfield. We were able to overcome all obstacles through perseverance and great teamwork. This was a collaboration between our Tucson and Sierra Vista offices which turned out to be a great opportunity to work side by side.
Roadway reconstruction consisted of new median islands, landscaping, a drainage structure, curb, sidewalk, curb access ramps, driveways, and street lighting. New traffic signals were installed at the Drachman and Speedway intersections as well as three bus pullouts that were constructed. In addition, a new water distribution system was constructed and the old system removed.
Many people had heard that Pima County invested about $20,000,000.00 to build a facility for World View, a company that launches “Space Bubbles” over 19 miles high into Earth’s stratosphere. As part of the job, new sewer, water, and dry utilities needed to be installed over three-quarters of a mile along the Aerospace Parkway, located between Hughes Access Road and Alvernon Way, which is about five miles south of our Tucson office. KE&G was the successful low bidder for the sewer installation and dry utility section of the work. In total, we installed utilities for Pima County Wastewater, Cox Communications, Tucson Electric Power, and Pima County Fiber Optics. On May 11, the site was cleared, and on May 16, underground crews got started with the new 8” sanitary sewer. Once the new sewer was installed, we immediately followed with the new dry utility joint trench installation. A hard deadline was set by Pima County to provide World View with the power and water needed to complete their building and remaining site work. This project received the APWA SAB 2016 award of merit under the Public Works Project of the Year Environmental Less than $5 Million categories.
SIERRA DENTAL IN SIERRA VISTA
KE&G completed site work for The Sierra Dental project in Sierra Vista. All work was completed by our Sierra Vista Team. Our team included Ben Carter, John Drake, Cesar Acuna, Rick McMahon, and Ramon Morales. The scope of work included the installation of SWPPP BMP’s, removal of the existing parking lot & improvements, cut to export 5400 CY, 100’ of 4” sewer with clean-outs, 312’ of 4” PVC fire line, 312’ of 2” copper water service, irrigation stub, backflow preventives, 200’ PVC storm drain (6-12”), 604’ of 48” CMP stormwater retention system, 75 CY grouted and dumped rip rap, 518 CY of 4” thick MAG ABC, 724 TN asphalt paving, and parking lot striping. Access was a challenge on this project with only one way in and one way out. The site was very small, which made for a congested construction area with multiple trades working around each other. This led to a request from the general contractor for pricing to pave the site in two phases, KE&G successfully completed this project as well.
HARRISON GREENWAY MULTI-USE PATHWAY
This project consisted of improvements of a new 3.2 miles long, 12-foot-wide asphalt multi-use pathway. The pathway starts on the South side of Irvington at an existing crosswalk and continues South across Valencia and links up with Mesquite Elementary School. This was a fast-paced project, with limited public impact, and promises to bring a safer exercising and leisure element to the area.
PANTANO RIVERPATH 5th STREET TO SPEEDWAY BLVD.
This project ran parallel to the Pantano Wash between the 5th St. Wash and Speedway Blvd. in Tucson. The project consisted of a 95-foot span prefabricated steel pedestrian bridge, as well as 1,250 feet of the asphalt path, decomposed granite paths, a ramada shade shelter, various landscape features, and project artwork.
22nd STREET SEWER AUGMENTATION
This project consisted of the installation of 5,485 LF of new 12-inch sanitary sewer. The selected stretch augmented was along 22nd Street from Alvernon Way, the downstream end, to Swan Road, the upstream end. The existing adjacent sewer line was 10 inches in diameter vitrified clay pipe (VCP) between Alvernon Way and Swan Road.
KE&Gs team identified the following key risk areas to address through the pre-construction phase of the project: traffic, utility coordination, and bypass routing. The team established relationships early on with the City of Tucson Department of Transportation (TDOT), Tucson Water, and worked with Kaneen Communications to connect area businesses and residents. To minimize traffic, KE&G decided to complete the project while avoiding rush hour traffic. Crews worked 4-10 hour shifts starting after 7:00 PM and day crews worked 8 hours per day while avoiding rush hour. Utility coordination was key during the project.
While construction was progressing, additional potholing was being completed at utility crossings in future construction areas. KE&G identified a 54-inch diameter concrete cylinder pipe water main which varied from the design by 2+ feet. KE&G brought the potential conflict to the attention of the owner, then proceeded to assist the design team with the modifications to eliminate any delays. The redesign was completed over a weekend and accepted on Monday morning in time for the redesign work to be started that night. To avoid traffic disruption while completing the sanitary sewer flow management, KE&G worked evening hours in addition to modifying the routing through drainage avoiding disruption of the 22nd Street & Swan Road intersection.
I-19/PIMA MINE ROAD
The I-19/Pima Mine Road bridge widening and resurfacing project is a $4.7 million consisting of almost 800 cubic yards of structural concrete removal and 22,000 square yards of pavement removal, ½ mile of paved, 2 lane detours, new lighting at bridge, 10 drilled shafts in excess of 50 feet in depth, 6 new bridge columns and 12 new bridge beams, abutment and pier cap extensions, forming and placement of almost 1,000 cubic yards of new, structural concrete, over 200,000 pounds of rebar and over 10,000 tons of asphalt. The project is located South of Tucson, near the Town of Sahuarita and was scheduled to take approximately 13 months to complete. The project is for ADOT and involves multiple agencies including the Tohono O’odham Nation, Union Pacific Railroad, Tucson Electric Power, the Town of Sahuarita, Central Arizona Project and the ASARCO Grupo Mexico.
VALENCIA ROAD WIDENING: ALVERNON WAY TO WILMOT ROAD
This project involved the widening and reconstruction of Valencia Road from Alvernon Way to Wilmot Road to improve safety, reduce congestion, improve operations and increase mobility. The project widened the existing roadway from four lanes to six lanes and included the widening of the bridge structure over the Union Pacific Railroad as well as the interchange at I-10 and Valencia Road. Other improvements included depressed landscaped medians, multi-use lanes, provisions for pedestrians, and landscaped shoulders.
The overall project included widening approximately 3.3 miles of roadway. Work included 300,000 cubic yards of mass excavation and re-compaction, the installation of 7,091 linear feet of 18 inch – 60-inch drainage pipe, 200 linear feet of 10-foot x 5-foot box culverts, bridge widening over the UPRR, and 4,750 linear feet of water line with multiple valves and tie-ins to Tucson Water. In addition, new traffic signals installed as well as 307,970 square yards of landscaping, 70,996 square feet of sidewalk, approximately 70,000 linear feet of concrete curb, and 70 curb access ramps.
CATERPILLAR TINAJA HILLS DRAINAGE REALIGNMENT
This project was to bring the existing private property site drainage way up to regulation standards. The scope included replacing the existing drainage channel with the larger concrete-lined channel, relocating the existing haul road, adding two new culvert crossings of 6 EA 72″ CMP culverts, constructing a new concrete inlet structure, new riprap outflow, and re-pave existing asphalt access road. This project was delivered in an abbreviated schedule window with an accelerated start date. Challenges included rock excavation, maintaining the ongoing owner heavy equipment haul roads and traffic, and maintaining a tight schedule.
INA ROAD AT SR-77 INTERSECTION IMPROVEMENT
KE&G worked for the Pima County Department of Transportation in conjunction with the Regional Transportation Authority, the Town of Oro Valley, and the Arizona Department of Transportation. The Ina Road at SR-77 intersection was the first-ever indirect left intersection to be constructed in the state of Arizona. This intersection is the second busiest intersection in Pima County, with over 96,000 vehicles passing through it daily. This project was designed to increase the capacity of the intersection by eliminating the designated left turn signal onto Oracle Road and the addition of dual right-turn lanes onto Oracle Road northbound.
It has been evident over the past few years how much the new traffic configuration has improved the general flow of traffic, decreased traveling delays, decreased west-bound traffic congestion on Ina Road, and decreased traffic cutting through neighborhoods adjacent to the intersection. The project included the installation of over 1,500 LF of storm drain, 15 new storm drain structures, 9,875 CY of roadway excavation, over 3,900 TONS of asphalt paving, a new bus pullout, two new indirect left-turn intersections, the reconstruction of the Ina Road/SR77 intersection signals, 6,100 LF of concrete curb, over 480 CY of hand placed rip rap, and 8,200 SF of decorative concrete pavers. The majority of this project was constructed at night, with working hours from 8:00 p.m. to 5:00 a.m., there was a tight 60 working day schedule. Even with 16 utility delays, 161 force account items, and 39 requests for information, this job was finished within the allotted contract time.
LA ESTANCIA PHASE 7
The scope of work included; earthwork, underground, concrete, and paving as part of New Development of 100 Lots for Richmond American Homes. Unique challenges: This project was built off of a 10-year-old set of plans that had been prepared by a firm that was no longer in business. KE&G worked closely with City personnel and a new Engineering Firm to ensure compliance with current standards. Many field fits and alterations were required due to plan errors and omissions.
SOUTHEAST INTERCEPTOR (SEI)
This CMAR project consists of installing approximately 4 miles of 36 inch to 48-inch sewer through the jurisdiction of Tucson and South Tucson. It involves augmenting a portion of the existing Southeast Interceptor (SEI) along 36th Street between 18th Street and Euclid Avenue. This Construction Manager at Risk (CMAR) project, started with pre-construction services to develop the routing for the almost three miles of sewer main that averaged 20 feet in depth through extensive utility corridors and congested urban areas. The design of this sewer line required the coordination with City of Tucson, City of South Tucson, ADOT, Tucson Water, Union Pacific Rail Road, City of Tucson Electrical, Kinder Morgan, Century Link, Comcast, and worked with Kaneen Communications to connect area businesses and residents.
This project also required phasing the construction into four ADEQ submittals to allow for the construction of the sewer main. After this project, the sewer main will also add two odor control structures and eliminate a chemical dosing unit that required additional material and maintenance to operate. In coordination with the City of Tucson, this project completed a future portion of the urban greenway project and also provided access for PC RWRD maintenance vehicles, all while beautifying the existing railroad right of way.
During construction, the project team installed the new sewer main up to 27 feet deep, crossed the largest water main in the City of Tucson, crossed large diameter high pressure gas lines, crossed railroad tracks, installed seven large diameter jack and bores, protected existing railroad tracks and a bridge, relocating existing waterlines, crossing numerous utilities, replacing curb/drainage/ADA ramps/sidewalks, repaving, restoring traffic signals, striping, and much more. To facilitate the sewer installation the project team developed and implemented a bypass plan that utilized gravity bypass to minimize costs/maintenance, installed and operated flow management that diverted all of the existing sewage from the existing Southeast Interceptor which is approximately 12 mgd.
This project will aid in the control of sewer flows for the potential development of the Aerospace corridor and allow for the redirection of flows for future repairs along the SEI.
During the design process, evaluation of existing utilities, traffic, and construction sequencing we completed to determine if boring and the method of boring utilized was adequate for each potential boring location. Each area evaluated these impacts, the associated costs, and risk associated to determine the optimum solution for the project.
Existing sewer lines in the area that was historically problematic were eliminated or repaired. These lines created long business connection services or odor problems that resulted in additional costs and maintenance for the County.
Another benefit of this project is the preparation for the new Old Nogales Sewer line which can be connected to the SEI without bypass pumping.
When unknown utilities were encountered, the project team was able to efficiently coordinate with local utilities to determine the solution and coordinate relocation with KE&G directly due to existing contracts in place with those utilities.
During the design phase, the project team developed a sound public relations program. Due to this program, the first three phases of this four-phase project have been completed with understanding and support of the surrounding residents. One of the biggest opponents of the project has now supported the project and commended our team on this program and the construction progress. Another significant development during the design phase was the coordination with multiple other construction projects that are planned or in progress in the area. These projects include private developer-funded projects directly adjacent to the SEI project and Pima County/City of Tucson projects that will be constructed after the SEI project is completed.
CORTARO FARMS AND MAGEE RD IMPROVEMENTS
The project consisted of a total of 1.95 miles of road improvements including 1.65 miles of Cortaro Farms Road/Magee Road, from Thornydale Road to Mona Lisa Road, and 0.30 miles of Shannon Road. The construction consisted of four lanes of roadway with medians, curbs, sidewalks, traffic signals, landscaping, irrigation, utility work, retaining walls, soil nail walls, noise walls, and drainage facilities. Also, improvements were made to the existing Canada del Oro Wash Bridge as well as the installation of a new concrete girder bridge over the Canada del Oro Wash. This project was completed approximately 50 days ahead of the allowable contract time and under budget. Two value engineering designs, as well as a revised ridge deck drain design, were submitted and approved by Pima County saving KE&G upwards of $30,000.00.