FM 521 Ground Storage Tank Expansion

2019 6 panel installation drone

Project Overview
About. Continued growth and increased demands on the water distribution system—along with planning for the distribution of future surface water—require increased storage capacity at the FM521 Ground Storage Tank. Accomplishing this requires expansion of the storage tank. This project is divided into two phases. Use of phases allowed for a narrower field of bidders and a lower cost of construction for firms that specialize in Ground Tank Storage construction.

Phase I included the installation of a 3.0 million gallon pre-stressed concrete storage tank. Additional storage at this location will allow the city to improve the operation of existing distribution by shaving water usage peaks, adding additional capacity to improve system pressure maintenance, and improve quality of delivered water.
Phase II addresses the build outpump sizing upon water model projections, revisions to the electrical system, pump controls, and the installation of fiber associated conduit.

Scope. The proposed project includes the installation of a third ground storage tank, related piping, upgrade of existing pumps, and controls to provide additional storage and increased firm capacity at the FM 521 Water Pressurization Facility. The Project includes a 1,600 ft. run of conduit and fiber to connect the plant to the fiber located on Shadow Creek Parkway and provide continuity with the conduit run from Broadway along the FM 521 Waterline.

Schedule

Phase 1

	*Base Line*	*Current*
*Design Start*	September 2017	January 2018
*Bid Start*	October 2018	September 2018
*Construction Start*	January 2019	January 2019
*Proposed Construction Completion*	January 2020	June 2020

Phase 2

	*Base Line*	*Current*
*Design Start*	March 2019	March 2019
*Proposed* *Bid Start*	July 2019	October 2019
*Proposed* *Construction Start*	January 2020	January 2020
*Proposed Construction Completion*	October 2020	December 2020

Budget and Funding

Below is the Budget and Funding Information for the project. Last updated August 2020.

Funding Sources
General Revenue - Cash	-
Certificates of Obligation	-
W/S Revenue Bonds	$2,912,500
Impact Fee - Debt	-
Impact Fee - Cash	$2,759,975
Other Funding Sources (Fund Balance)	$152,525
Total Funding Sources	$5,825,000

Expenditures
PER	-
Land	-
Design	$572,827
Construction	$5,000,430
Construction Materials Testing	$28,218
FF&E	-
Total Expenditures	$5,601,475

Project Balance/Contingency

$223,525

2020

August

Phase I Highlights:

Repair/replace asphalt driveway.
Install 16” inlet riser pipe for the new tank.
Sterilize the interior of the tank and fill tank with water.
Leak test was performed successfully on new GST.
Bacteria Test taken by COP Water Department confirmed negative results (passed).
Interior tank Mixers are up and running in all three tanks.
Substantial Completion was obtained on June 23, 2020, within schedule.
Deductive balancing change order for Phase I totaled $159,222.08 in savings to the project.
Retainage has been released to the Contractor
All close-out documents including: As-Builts, O&M manuals, Final Consent of Surety, Final Lien release, etc. delivered to City.

Upcoming Phase I Work Items:

Start up of the New Tank once controls software is updates and installed.

Phase II Highlights:

Installed all conduits for instrumentation on each of the three tanks.
Pulling wire through conduits for terminations at both ends
Connect power for control panel and mixers in all three tanks.
Mounting control panel inside maintenance building.
Exercised the valves.
Contractor will demobilize from the site until remaining equipment (pumps and generators) arrive. Pumps and Generator units are now becoming long lead time and delayed delivery items due to COVID issues with manufacturers. Staff is adapting by modifying specifications to utilize standard equipment sizes which in many cases are available on the shelf.

Upcoming Phase II Work Items:

Generator has been ordered, tentative for January 2021.
Demo existing generator and generator pad.
Build new Generator pad and install generator.
New Booster Pumps have been ordered, tentative install is for December.
Motor Control Center replacement will require a 2-week plant shutdown, coordination with the Water Production department is underway.
Fiberoptic conduit run to the water plant.

Read August 2020 memo

2020

April

Phase I: The initial phase of construction which is confined to the pre-cast concrete tank work is on schedule.

Phase II: The design for pumping and controls which was separated due to the specialty of the electrical and plant control work not belonging with the tank and piping construction.

Phase I Highlights:

Paint exterior of the tank.
City Logo painted on the tank.
Site grading and hydro seed of the construction site is complete.
All site concrete is complete, spillways poured.
New mixers are installed on all three tanks to circulate the water for better quality.
Installed 24" and 18" yard pipe to tie in the new tank.

Upcoming Phase I Work Items:

Repair/replace asphalt driveway.
Install 16" inlet riser pipe for the new tank.
Sterilize the interior of the tank and fill tank with water.
The project is scheduled for June 2020 to have the substantial walkthrough.

Phase II Highlights:

Contractor has mobilized to the site.
Trench for ductbank installation.
Placed red concrete for all three tank ductbanks.
Electrical rough-in to tanks including conduits for all three tank mixers.
Installed conduits for Tank #1.
Junction box for ductbank installed.

Upcoming Phase II Work Items:

Continue installing all conduits.
Pulling wire.
Install fiber conduits.
Mounting control panel inside maintenance building.

Read April 2020 memo

2019

November

This memo provides information regarding the award of the construction contract for Phase II of the FM 521 Ground Storage Tank (GST) Expansion project. Phase II includes upgrades to electrical instrumentation and control and upsizing of two pumps.

November 2019 memo

October

Highlights

Phase I Highlights:
• Hung Dome panels (tank roof)
• Formed and poured Dome slots
• Removed scaffolding from inside of tank (initial support structure required for tank roof)
• Start wire winding of the tank (wire reinforcing of tank wall panels)
• Shotcrete the tank walls with concrete covering wire windings
• Patch access holes in the tank.
• Pour dome donut/remove forms
• Pour concrete curb inside of the tank.

Upcoming Phase I Work Items:
• Haul off tools, equipment and surplus materials.
• Pressure wash the tank
• Paint exterior of tank
• Grade form and pour over flow spillway
• Repair/replace asphalt driveway at the end of the job.
• Any damages to the wood fence will be repaired in this phase of work.

Phase II Highlights:
• Electrical and Control Design contract was awarded to Costello, Inc. is in the amount of $278,502 on
February 25, 2019.
• Contract was amendment 9/10/2019 for $ 57,225 to add additional VFDs and new SCADA programming to
the project per recommendations from the Water Model.
• Technical Review Committee meeting was held September 24, 2019.
• Consultant currently addressing final comments to the 95% set.

Upcoming Phase II Work Items:
• Current Bid Schedule
o First Advertisement: October 9th
o Second Advertisement: October 16th
o Mandatory Pre-Bid meeting: October 17th
o Bid Opening October 31st
• Anticipated Council Award Date: 1
st meeting in November
• Construction Phase 300 days (Final Completion September 2020)

October 2019 memo

June

Highlights

2019 6 scaffolding

Phase I Highlights
- Completed the select-fill tank pad
- Installed Tank pad rebar over the filter fabric and pea ravel
- Formed and poured concrete tank pad; placed 280 yards
- Relocated hydrotank
- Wed cured tank pad concrete
- Poured casting beds for tank walls
- Built scaffolding in the tank center for improved access within tank
- Mobilized crane to the site for setting tank walls
- Upcoming Items
  - Start Wire wind of the wall panels
  - Hang dome panels
  - Form and pour dome slots
Phase II Highlights
- Award
  - Electrical and Control Design contract awarded to Costello, Inc.
    - Award for $278,502
- Design
  - Established on accelerated scheduled due to need to have construction phase ii mobilized prior to the completnion of the tank in phase i
  - City review of 90% plans/specs completed
  - 90% plans submitted for recquired TCE 60 day review process
- Upcoming
  - Completion of TCEQ review and addressing of comments
  - 95% Technical Review
  - Finalization of plans/specs

June 2019 memo.

April

Phase I Highlights
- Contractor had survey crew lay out construction areas and set up SWPPP protection for the site
- Five foot excavation site for the tank slab and foundation completed
  - 500 truckloads of excavated aterial hauled offsite
- Currently importing and compacting select fill for the tank pad
- Upcoming Items
  - Continue to haul in select materials to build up the tank pads
  - Form and pour concrete tank pad
  - Relocate hydrotank
  - Start on construction of tank walls
Phase II Highlights
- Electrical nd Control design contract awarded to Constello, Inc
  - $275,502
- Letter Report finalized March 20^th, documenting the basis of design (operational parameters) for the water plant’s electrical, pumps, VFD, and generator
- Design established on an accelerated schedule due to the need to have phase II construction mobilize prior to the completion of the phase I tank that is currently underway
- Upcoming Items
  - 90% plans to follow in early May for City review

April 2019 memo

February

Award for construction to Costello Engineering
Proposal for design addresses
- Build out pump sizing based upon water model projections
- Revisions to the electrical system
- Pump controls
- Installation of fiber and associated conduit
Services
- Basic Services
  - Preliminary Engineering - $4,655 (Lump Sum)
  - Final Design Services - $42,180 (Lump Sum)
  - Bid Phase Services - $5,040 (T&M, Hourly not to Exceed)
  - Construction Phase Services - $26,420 (T&M, Hourly not to Exceed)
- Additional Services
  - Topographic Surveying - $6,000 (Lump Sum)
  - Easements - $5,000 (assume 2 easement @ $2,500/easement) if directed by City
  - Electrical/Controls Preliminary Engineering - $13,508 (Lump Sum)
  - Electrical/Controls Final Design Services - $130,856 (Lump Sum)
  - Electrical/Controls Bid Phase Services - $3,080 (T&M, Hourly, NTE)
  - Electrical/Controls Construction Phase Services - $37,763 (T&M, Hourly, NTE)
  - Reimbursable Expenses - $4,000 as authorized by City (T&M, Not to Exceed)
Schedule
- The Phase II design completion and supplementary bid and award are scheduled to coincide with the completion of Phase I tank construction. As to begin full utilization of the newly constructed tank as soon as possible without overlap of trades.

February 2019 memo.