Before the project could begin, an initial study was performed by Burns & McDonnell to determine facility improvement strategy and support in the programming of total project costs. Based on the study, the client chose to utilize full direct-hire EPC delivery services provided by Burns & McDonnell and AZCO for the entire design and construction project. Based on the results of a site inspection/evaluation, the project team’s highest priority was replacing the bottom of one of the aboveground storage tanks. An overall assessment prompted the consortium to work with Burns & McDonnell on a plan for reconfiguring both the on- and off-airport fuel facilities.
But the first order of business was putting a new bottom in the largest tank, which took about 10 months. It was key to address the tank bottom and permitting issues quickly to confirm the long-term use of the facility.
While the first and largest tank bottom was being replaced, design continued on the remaining portions of the project. Identifying long lead items — some up to 36 weeks — allowed pieces to be procured while the remaining design and other construction was completed. Once a new plan was agreed upon, preliminary design, full detailed design and long lead procurement of special equipment followed. With an EPC approach, the design and construction team was able to complete the project while minimizing service disruptions.
After design and procurement, AZCO completed fabrication and construction of the mechanical scope of work and heavy equipment lifts. AZCO leveraged its pipe fabrication capabilities at its shop in Appleton, Wisconsin — improving production efficiency, quality and safety of the overall installation of facility piping.
The scope of construction work included demolition of two existing 40,000-gallon underground storage tanks, aboveground and underground piping, valves, pumps, filter separators, and a 500-gallon waste tank. The refueler loading system was also modified to directly feed it from the hydrant system while maintaining operations on the active airfield.