CIPP and Tunneling contractor SAK Construction completes challenging $10.875 million MSD Lemay tunnel

SAK Digs In to Complete Stalled Excavation Work For Lemay Wastewater Treatment Plant Wet Weather Expansion Outfall Sewer Project

 

ST. LOUIS (June  5, 2012) – When unexpected ground conditions put a sudden halt to initial efforts to excavate a new 558-foot-long, 16-foot-diameter tunnel leading from the Lemay Wastewater Treatment Plant, the Metropolitan St. Louis Sewer District reissued the project for bid to find a contractor equipped for the challenge.  The project award, which included pipe installation as well as tunneling, then went to SAK Construction, a national pipeline rehabilitation, CIPP and tunneling services contractor headquartered in O’Fallon, Mo.  SAK began work in December 2010 and completed the $10.875 million project, formally named the Lemay Wastewater Treatment Plant Wet Weather Expansion Outfall Sewer project, in approximately 16 months.  The completed outfall sewer line is now in service, providing a new effluent discharge line from the Lemay Wastewater Treatment Plant to a structure on the west bank of the Mississippi.

The scope of work on this project included an extensive tunnel excavation of 381 linear feet. A tunnel boring machine excavated the tunnel to just over 11 feet; crews then went in using non-explosive and explosive rock methods to further widen the tunnel to a 16-foot-diameter horseshoe shape to accommodate the installation of concrete pipe segments that were 12 feet long and 132 inches in diameter.  In addition to difficult ground conditions, challenges encountered and resolved by the SAK team included the discovery of a previously unknown and unmarked sanitary tunnel, which caused flooding during tunnel excavation and required the erection of a temporary bypass pumping operation.

The project was designed by Black & Veatch. The construction management team representing MSD on this project was KAI Design & Build.

SAK is one of the fastest growing, privately held pipeline rehabilitation, CIPP and tunneling contractors in the U.S., with 300 employees working on projects in 28 states.  SAK provides specialized, high-demand services ranging from large diameter tunneling to the full spectrum of current trenchless or “no dig” technologies, including CIPP (cured-in-place pipe) pipeline rehabilitation for sanitary and storm sewers.  SAK is a contract partner of three cooperative purchasing organizations based in Texas.  The organizations, which serve government entities nationwide, include Choice Facility Partners and The Cooperative Purchasing Network, both in Houston, and BuyBoard in Austin.  SAK clients include a variety of city, county and state agencies; industrial sectors; the federal government and municipalities; and water and sewer cooperatives coast-to-coast.

In the most recent annual ENR (Engineering News Record) survey of national specialty contractors, SAK Construction was named to two separate lists, ranking 7 on “The Top 20 Firms in Utility” and 214 on “The Top 600 Specialty Contractors.”