Construction Today - July 2016 - 35

District and City of Dallas Water Utilities, is ultimately anticipated
to stretch 150 miles. "The Dallas/Fort Worth area has experienced
significant growth," Zupan says. "This project will increase the area's
water capacity and help it meet current demand as well as projected
future needs."
The company thus far has placed roughly 54,000 of a total 68,000
linear feet of 108-inch diameter pipe underground. Of those 54,000
linear feet, roughly 2,500 linear feet was placed using tunneling and
boring methods, as the pipeline crosses highways at five different
points. Tunnels were bored at roughly 144 inches in diameter to
accommodate the pipeline, he adds.
Pipe was sourced from four different manufacturers, each of
whom worked closely with Thalle. "The pipe guys had a very large
scope, in that they worked with us as well as each other to ensure
they delivered in a timely manner," Zupan says.
In addition to the pipes, each of which measures 50 feet in length,
the company will install three 108-inch diameter gate valves, the
largest of their kind to be installed in the United States, he adds.
Thalle is filling the empty trench spaces around the pipe with
a combination of rock embedment and flowable concrete slurry
the company is producing on-site in a concrete batch plant. "The
amount of soil cement required for this project, along with the large
volume of flowable fill specified in certain areas made it necessary
for us to not only be able to batch this material on site, but also manage and transport it ourselves," Zupan says.

The MBR consists of three 150-million gallon earthen reservoirs as
well as six inlet/outlet structures - two at each reservoir - and more
than a mile of piping. Thalle is also placing electrical, instrumentation and control infrastructure related to the MBR, Zupan says.
The MBR involves 840,000 yards of excavation, and will require
180,000 yards of clay core and 560 cubic yards of embankment. "This
is a pretty massive civil undertaking," he adds.
Thalle is using a combination of trackhoes, rippers, reclaiming
machines to perform the excavation. The material being excavated
in this manner - which includes clay and limestone - is then transported to an on-site facility, where it is crushed and screened. "We're
processing material into as fine a form as we can, which we can then
use to build the reservoirs, instead of having to bring materials in,"
Zupan says.
Excavating and processing the materials for the MBR posed a
challenge for crews because of the enormity of the project and the
logistics required to move and process materials on site.
The pipeline placement is also challenging, as it winds through
both populated and unpopulated areas, going through creeks, ponds
and highways. Thalle is coordinating pipeline placement with a
number of local communities, agencies, homeowners associations
and commissions, he adds.
Crews have also needed to work around weather conditions. "Last
year was the wettest in Texas history," Zupan notes. "When you're
dealing with underground utility work, that can be very difficult."

'A Massive Undertaking'
The pipeline placement is one of two major portions of Thalle's
work on the IPL. The company is also excavating the Midlothian
Balancing Reservoir (MBR), which will hold water for later processing. The MBR represents roughly 50 percent of the overall contract
cost, Thalle notes.
Pipeline placement and excavation
are the two major aspects of
Thalle's work on the project.

«

35

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Table of Contents for the Digital Edition of Construction Today - July 2016

Contents
Construction Today - July 2016 - Cover1
Construction Today - July 2016 - Cover2
Construction Today - July 2016 - 1
Construction Today - July 2016 - Contents
Construction Today - July 2016 - 3
Construction Today - July 2016 - 4
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