For the past several years, the city of Calgary has looked to Graham Construction for many of its infrastructure needs. In 2005, the company took a lead role, with a total of eight separate contracts in the $303 million construction of the city’s Pine Creek wastewater plant, which services Calgary’s south end. That project – which was completed in 2010 – led to a number of smaller projects including the replacement of clarifier mechanisms and other components at several of the other city facilities.

“We’ve been successful on the maintenance side for the city,” says Andrew Buchner, a project manager for the construction manager and general contractor. 

Graham Construction in December 2014 continued its long-term relationship with the city when it began work on a $93 million upgrade to the Bonnybrook Wastewater Treatment Plant. The facility   – the largest of the city’s wastewater treatment plants – serves 800,000 residents and treats about 700 megaliters per day at peak flows.

The project closely follows the completion of a $65 million 19,300-square-foot headworks building – the main point of influent entry into the plant – last year. “That project went extremely well, and the success of it led us to be involved in this upgrade,” Buchner says. 

Tight Coordination

The Bonnybrook plant was first constructed in 1918, expanded in 1954 and upgraded during the 1980s. Graham’s contract includes upgrading components in two of the plant’s liquid trains, including installing new secondary clarifier mechanisms and clarifier tanks. In addition, new electrical systems and instrumentation will be placed in the facility. “We’re upgrading with the ultimate goal of building out the existing plant’s capacity,” Buchner notes. 

The upgrade project is projected to conclude in September 2018, and will be immediately followed by a plant expansion project. Graham is serving as the general contractor on the plant upgrade, and is contracted to provide construction management services on the expansion project. The expansion project is slated to begin in 2017 and conclude in 2022. 

Current work on the site includes pouring concrete and underground excavation. Civil work is anticipated to conclude next year. 

One challenge faced by Graham Construction is the phasing of work around plant demand. Portions of the plant infrastructure such as piping, pumps, electrical systems and controls cannot be shut down and replaced until low-flow periods. These periods typically run from April 1 through May 31, and from July 1 to Sept. 1. “We don’t want to impact the efficiency of the plant,” Buchner says. 

The limited laydown space available in the plant is also a challenge. One of the upgrades involves constructing a new secondary pump house in a tight space beneath an active liquid channel in the plant while that channel remains operational. Graham is staging equipment and materials for this – and every other – portion of the project. 

“With multiple contracts going on at the site, some of which Graham is handling and some of which we are not, the shared space gets to be tight,” he adds.

Graham is communicating with not only its subcontractors and vendors, but also other contractors working on plant-related projects. “We’ve come up with a pretty good team both on our side and [competitors’] who are willing to work together and make sure things get done,” Buchner notes. 

‘Making it Happen’

Graham Construction has delivered numerous wastewater treatment plants throughout North America that provide communities with innovative technology for treating water more efficiently and delivering high-quality standards expected in terms of water quality and environmental management.

The company, initially founded in 1926, is today a growing and diversified employee-owned organization of roughly 1,200 employees. Buchner believes the company’s core values of commitment, integrity and reliability – as exemplified by its staff – are why Calgary has become a regular client. “I think the city recognizes that Graham is dedicated to making sure its best interests are met,” he says. “If they need it, we will make it happen.”