Trickling Filter Rehabilitation

Project Details

  • Project Type:
    Waste Water Filter Rehabilitation
  • Location:
    Fountain Valley, CA
  • Delivery Method:
    Design-Bid-Build
  • Design Engineer:
    Black & Veatch
  • Constructed Value:
    $35,185,946
  • Completed:
    May 2008
  • Project Highlights:
    • Filanc collaborated with OCSD to value engineer a more durable concrete column cover at a reduced cost.
    • Proper planning allowed Filanc to successfully complete numerous tie-ins and tunneling without interrupting plant operations.
    • Active communication reduced hurdles during the construction phase to meet the desired schedule deadlines.
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Trickling Filter Rehabilitation
and New Clarifiers

Orange County Sanitation District

The Filanc P1-76 project team was very professional and maintained good working relationships with all OCSD staff including individuals from construction management, design engineering, inspection, and operations and maintenance departments. Filanc maintained a high level of safety, stormwater management compliance, and quality control practices. OCSD considers the P1-76 project a success and commends Filanc on their work ethics and efforts. OCSD looks forward to working with Filanc in the future.
Brian Bingman
Senior Engineer, Orange County Sanitation District
Since the 1950s the Orange County Sanitation District (OCSD) has provided wastewater services to an ever growing population in Orange County, California. OCSD owns and operates two regional plants, the Fountain Valley and the Huntington Beach Wastewater Reclamation Facilities, which treat wastewater from residential, commercial, and industrial sources, providing Orange County with highly-treated wastewater effluent.

In keeping with their commitment to quality, OCSD continues to modify operations to meet a higher level of secondary treatment standards for its effluent. OCSD contracted with J.R. Filanc Construction to complete the Trickling Filter Rehabilitation and New Clarifiers project at its Fountain Valley facility. This $35 million project involved the renovation and expansion of OCSD’s existing 30 million gallons per day (MGD) secondary treatment plant.

Work on the project included construction of two new 166-foot diameter plastic media trickling filters, a trickling filter pump station, two new 160-foot diameter secondary clarifiers, a sludge/scum pump station, a power building with backup diesel-powered generator, all associated piping (up to 71-inches in diameter), four junction and yard structures, and the demolition of various structures and systems. The trickling filter support system initially required T-Lock covered concrete columns. Filanc worked with the owner to value engineer an alternative solution to provide a more durable cover at a reduced cost.

The cooperative relationship between Filanc and OCSD’s construction management staff helped to overcome the many hurdles that were encountered during construction and kept the project on schedule. Despite its various challenges, OCSD’s Fountain Valley Facility remained fully functional throughout construction. This Trickling Filter project was the first of seven milestones for OCSD to achieve full secondary treatment compliance.

Meeting Project Challenges:

Filanc met the project’s critical milestones through client communication, efficient project management, and construction practices. The sequencing of construction was critical to insure that no unforeseen delays would impact operations. This required Filanc to create and maintain a very detailed schedule for all self-performed and subcontracted work.

  • Schedule Challenges: The project was constructed during an unprecedented boom in residential and commercial construction, which posed difficulties in keeping the project on schedule. Shortages of Portland cement, rebar, and stainless steel materials were common-place, but with excellent communication and scheduling between Filanc and its subcontractors and suppliers, the delays caused by these shortages were minimal. A critical milestone for OCSD was to have the main process units in service to meet a February 2005 consent decree. Filanc met this critical date and ensured all performance levels were met.
  • Minimizing Interruptions to Plant Operations: Another challenge the team overcame was the construction of structures and piping in excess of 20-feet deep that were completed while minimizing impacts to the operational plant. Numerous tie-ins, as well as tunneling under an existing utility trench and the dewatering of existing groundwater, all posed potential interruptions to plant operations. However, proper planning prior to starting the project allowed the team to successfully meet each of these challenges.
  • Safety: Filanc and OCSD’s safety staff worked closely together to ensure safety during construction. The project went over 145,812 man-hours and was completed without any lost time incidents. Filanc is committed to all aspects of safety on the job site including risk control, active employee participation, safety training, work site hazard identification and control, and a continuously updated safety program.