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PROJECT TYPE
LOCATION
Montville, CT
PROJECT COMPLETED
November 2024
DOWNLOAD PROJECT
PROLONGING THE LIFE OF MUNICIPAL INFRASTRUCTURE
The Montville Water Pollution Control Authority (WPCA) in Connecticut was facing a challenge with its aging distribution boxes (D-Boxes), critical components in the wastewater treatment process. With these tanks showing signs of significant deterioration, the WPCA needed a solution to extend their service life and avoid costly replacements. After reaching out to Savy & Sons for our expertise in coatings and linings, we quickly mobilized to design and implement a comprehensive rehabilitation plan. This partnership not only addressed immediate concerns but also ensured the long-term durability of their infrastructure.
PROBLEM
The Montville WPCA’s distribution boxes, part of the wastewater treatment plant, were facing the natural wear and tear of aging infrastructure. The existing tanks had reached a point where their structural integrity was compromised, and continued operation would lead to more severe issues, including the potential for system failures. The WPCA needed a solution that would prolong the life of these essential components, ensuring that they could continue to serve the community without major disruptions.
Given our extensive experience with industrial coatings, the WPCA reached out to Savy & Sons to provide a solution that would address both the structural and functional needs of the D-Boxes. Our goal was to repair, rehabilitate, and protect the existing infrastructure to extend its service life for many more years.
SOLUTION
Savy & Sons provided a specialized approach to the rehabilitation of the D-Boxes, using advanced coatings and linings to restore the tanks’ structural integrity and functionality. The project involved several key phases:
- Waterblasting: Ultra-high pressure water blasting was used to remove debris, contaminants, and deteriorated material from the D-Box surfaces. This crucial step ensured a clean surface for further repairs and coating application.
- Rebar Repair & Concrete Rebuilding: Any damaged rebar was repaired, and concrete was rebuilt to restore the strength of the tanks before resurfacing.
- Coatings Application: A custom-built plural component polyurethane proportioner was used to apply 800 mils of Sprayroq Spray Wall. This durable, chemical-resistant coating created a long-lasting barrier, effectively extending the lifespan of the tanks and protecting them from further deterioration.
- Bypass System: A specialized bypass system was engineered to divert wastewater around the treatment plant during the rehabilitation process, ensuring there was no disruption to plant operations.
PROJECT EXECUTION
The project was completed within one month, thanks to our efficient project management and the use of specialized tools and equipment. Key steps included:
- Ultra-High Pressure Water Blasting: To clean and prepare the surfaces for treatment.
- Concrete and Rebar Repairs: Restoring the structural integrity of the D-Boxes.
- Polyurethane Coatings: A custom solution to protect the infrastructure from future damage and corrosion.
- Bypass System: To ensure uninterrupted wastewater treatment during the project.
We took careful measures to maintain plant operations without disruption, ensuring that no wastewater treatment was compromised during the rehabilitation process.
RESULTS
The Montville WPCA D-Box Rehabilitation project was completed successfully within the one-month timeline, with the following key results:
- Extended Lifespan: The application of high-quality industrial coatings has significantly prolonged the service life of the D-Boxes, allowing the WPCA to avoid costly and disruptive replacements.
- Operational Continuity: The specialized bypass system ensured that wastewater treatment continued uninterrupted throughout the project, minimizing any potential downtime.
- Improved Structural Integrity: The combination of repairs and coatings has strengthened the D-Boxes, ensuring they are better equipped to withstand harsh wastewater conditions for years to come.
This project demonstrated the value of preventative maintenance and the benefits of using specialized coatings to protect and extend the life of municipal infrastructure.
KEY TAKEAWAYS
The Montville WPCA D-Box Rehabilitation project underscores the importance of proactive maintenance and the role of durable coatings in protecting municipal infrastructure. By utilizing our expertise in coatings and linings, we were able to solve the WPCA’s immediate challenges while providing a long-term solution that will continue to serve the community for years to come.
Savy & Sons remains committed to providing high-quality, sustainable solutions for municipal and industrial infrastructure, helping clients protect their assets and improve system reliability.
“The Town of Montville (Town) Water Pollution Control Authority (WPCA) conducted a structural condition assessment of two reinforced concrete distribution boxes at the Town Water Pollution Control Facility (WPCF). Each structure has solid covers and has exhibited moderate to severe concrete deterioration. The purpose of this assessment was to evaluate the structural integrity, degree of concrete deterioration, and extent of exposed/corroded reinforcing steel (rebar) for each distribution box, and to provide recommendations for either replacement or repairs along with a repair design strategy.
In general, these distribution boxes were found to be structurally sound. However, the interior, above-water line concrete surfaces were found to be in very poor condition with severe erosion and deterioration resulting from steady exposure to (trapped) hydrogen sulfide over many years.
Significant thought was made to propose the best option; replacement versus repair. Replacement included the decommissioning and then replacing with a single structure to act as both a flow blending and distribution structure. Repair options included an initial wet (mud) coat to the concrete surface after cleaning and then a structural/sealant final coat.
It was critical that this work be performed in the very near term to avoid the potential for structural and/or process failure. The replacement/rehabilitation had to be completed in a limited time period due to the (over 2 million gallons per day) influent bypass required for work. Additionally, it was apparent that the job had to be finished before the New England winter. The work had completed in a tightly choreographed work sequence to establish the bypass and then complete work in the two structures.
It was decided that rehabilitation of the existing two tanks was the viable option. After the initial cleaning of the concrete faces, the buildup of the wall with an appropriate concrete material was added. Finally, the finish coat (epoxy, 80-mls) completed the repair.
The in-situ repair allowed the Town WPCF to maintain quality effluent. The overall plant downtime was 6 weeks. The tanks are coated thus sealing the concrete from the harmful gas and are expected to offer usage well into the future.
The Montville WPCF flow structures were improved by the timely application of the in-situ remedy- concrete coating by Savy & Sons, Inc.to old/failing concrete. It’s great to know that the tanks no longer represent a liability due to failure.”
ABOUT SAVY & SONS
As a family-owned and operated business, Savy & Sons has set the quality standard for three generations, providing masonry restoration, waterproofing solutions, and infrastructure repair for commercial, educational, and municipal customers.
With our service-first approach to all work, we’ve built a stellar reputation for quality, craftsmanship, and service. Our skilled team ensures that all projects are completed on time, within budget, and to our own demanding standards.
OUR MISSION
Our top priority is to solve problems with unmatched customer service.
OUR GOALS
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QUALITY
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SAFETY
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INTEGRITY
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