“Green” Waste Landfill Expansion Project Completed
Early in DBA’s history of constructing work in Phoenix, Vulcan Materials Company became an important client. DBA crews have completed literally dozens of projects of all types and sizes at various Vulcan sites over the past 20 years and this year was no exception.
DBA crews recently completed a large earthwork project for Vulcan at their Avondale Pit site (Indian School Road & El Mirage Road) to establish a new Cell #5 at the landfill, part of a Land Reclamation Project. The project’s scope included:
- Mass excavation, removal and grading of 137,000 CY to create the new cell
- 52,000 SY of grading for the bottom and slopes of the new cell
- Excavation of 830 LF of anchor trench for liner burial
- 608 LF of 6″ diameter leachate pipe
- 260 LF of 6″ diameter side slope rise pipe
- 260 LF of 18″ diameter side slope rise pipe
- Construction of 3 concrete bollards
- Installation of pipe stands
This project was on the heels of another project we completed for Vulcan at their Dysart Road and Southern Avenue pit where DBA completed earthwork and drainage improvements by removing silt, installing new rip-rap and stabilizing an existing slope at the materials pit. A new roadway was also established along the top of the pit.
Work Continues at Palo Verde Nuclear Generating Station
For funding reasons at Arizona Public Service (APS), the original $1.3 million Make-Up / Blowdown Hypochlorite Trench Structures project was broken into two phases. The first phase, “Trench #20” started in late 2015 and the second phase, “Trench #2″ started in early 2016. The scope of work included digging two large trenches (315 LF and 140 LF, respectively) that were then compacted. Each trench required outfitting of rebar-reinforced, precast, concrete vaults running the entire distance to house pipes carrying sulfuric acid and water to the main cooling towers. Pipe sizes ranged from 1/2″ to 4” in diameter. Once piping was installed, the entire system was checked for leaks and inspected. The final phase of the project included the forming of cast-in-place concrete lids for the entire system that included steel grating for maintenance access.
Industrial Plant Modifications Complete
A recent contract with New West Oil Company was completed by DBA at their plant in Glendale, Arizona. The project scope included:
- Dismantle an existing gantry crane (5 sections) and remove to an off-site location for recycling
- Demolish existing concrete foundations
- Compact soil and prepare subgrade (120 CY of fill)
- Form and place new concrete two-ramp loading dock including dock leveling pits
- Form and place new reinforced concrete fuel storage slabs for two 10,000-gallon fuel tanks
- Excavate trench for 1,000 LF fuel slab conduit
- Construct 29 – 4″ pipe bollards
- Remove interior steel beams, steel door threshold, and steel door
- Widen and install new steel door
- Install new steel door header
- Install 140 LF of handrail
Miscellaneous Mine Construction Work
Various Locations across Arizona – Since 2004, DBA has been providing heavy civil construction services for the Arizona mining industry both as a prime contractor and as a concrete subcontractor. Projects have varied in size from very small repairs to large pit operation erosion control. The following projects have been completed by DBA over the past 9 years and are examples of the expertise we provide to the industry.
- Safford Phase II Temporary Haul Road Bridge, Freeport-McMorRan—DBA provided construction of a temporary, steel deck bridge (1,650 SF) for heavy equipment working at the leach pad to span the mine’s existing conveyor system. Work included construction of the bridge abutments, the erection of the steel girders and bridge decking, and bridge barrier installation. Our scope also included the demolition and removal of the temporary bridge structure once the leach pad was fully constructed.
- Clarkdale Iron King Mine Concrete Headwall Inlet Structure & Thrust Blocks, Phelps Dodge —Complete construction of concrete headwall to support 48” dia. corrugated steel pipe in a trapezoidal shape (21’ at top to 5’ at bottom), install steel trash rack, and construct three thrust blocks at the pipe elbows.
- Klondyke Upper Tailing Pile, Erosion Protection, Bureau of Land Management—Responsible for the placement of 3,200 CY of gabion baskets and geo-textile fabric to assist with the prevention of tailing pile erosion into nearby streams and creeks. Additional work included roadway maintenance along Klondyke Road.
- Clifton Shotcrete, Phelps Dodge—Shotcrete application for tailing pile.
- Morenci Geology Building Parking Lot, Freeport-McMorRan—Project included potholing to identify existing utilities, surveying, grading and placement of PCCP for parking lot (approx. 1,585 SF), concrete roll curb & gutter.
- Various Projects, Mining Operations, Vulcan Materials—Since 2004, DBA has completed more than 25 task orders at Vulcan Materials sites. Projects include:
Concrete heavy equipment pad joint repair
Construction of a concrete hauling apron
24th Street facility screening
Indian School Road facility grading
Replacement of truck cleanout area concrete apron
24th Street facility west pit earthwork & install HDPE piping
Rio Salado scale house concrete pad replacement
Black Angus pit facility excavation (121,000 CY)
Rio Salado facility screening
CMC Steel – Roadway 1, Roadway 6 & Lower Scrap Yard Road
CMC Steel, Mesa, AZ – Beginning in August, 2012, DBA Construction, Inc. was contracted by CMC Steel Arizona (a division of Commercial Metals Company) to provide multiple design-build task orders for their sophisticated metals manufacturing campus in Mesa, Arizona.
One of the more critical task orders included the construction of three (3) on-campus roadways (Roadway 1, 6 and the Lower Scrapyard Roadway) consisting of:
- Removal of existing asphalt pavement
- Regrading and compacting
- Placement with 8” thick Portland cement concrete pavement
- Placement of double rebar mattes to support heavy equipment
- Drainage improvements
Total length of the roads exceeded 2,600 LF.
CMC Steel – On-Call Plant Maintenance Services – Concrete Repairs – Phase 2
CMC Steel, Mesa, AZ – Continuing our long-standing relationship with CMC Steel, DBA was contracted in 2012 to complete 8 additional task orders for CMC’s micro steel mill and rebar production facility in Mesa, Arizona. The mill utilizes recycled scrap metal to melt down and reconstitute, through a patented process, which is then formed on-site into various sizes of rebar for construction projects and grapevine stakes for agriculture.
DBA was contracted to utilize in-house guide specifications to field design and construct the following projects:
- Lower Scrap Yard Access Road – Construct a 1,700 LF of 20’ wide PCCP roadway for heavy truck traffic. The roadway section consists of 12” thick PCCP with double-mat rebar over 8” of ABC. To withstand the heavy trucks with full scrap metal loads, the road required transverse and logitudinal rebar placement at 1’ on center, each way.
- Track-Out Grizzly – Construct a concrete pit with steel grating to shake mud and other dust producing materials from trucks (20’ x 12’ x 8” thick PCCP).
- Scrap Slab Extension – A 38’ addition to an existing 215’ x 30’ wide slab with 10” thick concrete over single-mat #8 rebar 6” on center, each way. The slab also called for 41 rails embedded in the concrete to keep heavy equipment from damaging the concrete finish.
- Drying Bunker – Construction of a 50’ x 70’ 3-sided structure with 10’ high walls and 8” thick concrete utilized as a drying bed for by-products of the steel milling process.
- Billet Reject Slab – PCCP slab (75’ x 25’ x 8” thick with single rebar mat) to hold rejected materials from steel mill processing.
- Flume Slab Extension and Driveway Extension to Roadway 6 – 10’ x 20’ PCCP slab with two rails embedded to protect slab from heavy equipment damage and a driveway connection of 22’ x 50’ long with 8” thick PCCP.
- Roadway 6 Addition – 510’ x 22’ wide roadway addition using 8” thick PCCP, single-mat rebar including curb and gutter.
- Sweeping Bunker Pad – 40’ x 40’ square area requiring earthmoving and compaction to support magnetic sweeping operations at the plant.
CMC Steel – On-Call Plant Maintenance Services – General Services
CMC Steel, Mesa, AZ – Beginning in August, 2012, DBA Construction, Inc. was contracted by CMC Steel Arizona (a division of Commercial Metals Company) to provide multiple design-build task orders for their sophisticated metals manufacturing campus in Mesa, Arizona.
Task orders included:
- Demolish & reconstruct failing concrete floor under billet line with new subgrade and reinforced concrete section
- Excavation, soil recompaction & replacement of tank foundations (10’ x 10’ x 8” thick)
- Concrete foundation and block-outs to expand billet reject table
- Placement of a 35’ x 30’ concrete forklift apron
- Slag Pit rehabilitation which included excavation, reinforcement, and concrete placement
- Construction of an on-campus roadway (Roadway 6) to consist of removal of existing asphalt pavement, replace with 8” PCCP and drainage improvements
To date, one of the most critical task orders consisted of the construction of a 5’ x 5’ x 3’ concrete foundation spanning an existing 20’ deep plume running underneath the billet line in the plant. The work consisted of installing a steel plate and angle system that would serve as a work platorm over the plume and eventually serve as the formwork for the foundation itself.
CalPortland – Sand & Gravel Pit Reclamation Project
CalPortland Co., Goodyear, AZ – Beginning in September, 2011, DBA was contracted by CalPortland Company to initiate plant reclamation efforts at its Bullard Pit operations in Goodyear, Arizona. The pit, owned by the Buckeye Water Conservation & Drainage District, the Flood Control District of Maricopa County, and other local stakeholders was leased to CalPortland and other ready-mix operators to produce aggregates (sand and gravel) for construction projects in the greater Phoenix metropolitan area.
After several decades of operation, CalPortland did not want to renew their lease and as a result the landowners were forced to reclaim the pit, return it to its natural state, and utilize it as a reservoir for irrigation water and to provide a regional lake for recreational purposes.
Inspection of the pit by the owners required extensive earthmoving operations which included the removal of a 400-foot slope along one side of the pit. Once the owners’ investigations were complete, reclamation of the vertical walls on three sides of the pit for crushing at the existing plant was provided. In order to meet the stakeholders’ critical deadline, DBA crews worked day and night shifts to complete all necessary earthwork on the 53-acre site.
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