Top Jobs 2020 Water Distribution Winner: Water System Expansion to Springfield, TN-Contract 3 24-in. Water Pipeline

EDITOR’S NOTE: In each issue, Utility Contractor will profile NUCA’s Top Job winners. These projects present the association’s best and most innovative work that keep our country’s utility networks operating at peak performance. To nominate your project for Top Jobs, visit: nuca.com/topjobs
ductile iron water pipeline
Cleary Construction installed approximately 20 miles of 24-in. ductile iron water pipeline from Guthrie, Kentucky, to Springfield, Tennessee.

Project at-a-Glance

Project Name: Water System Expansion to Springfield, TN-Contract 3 24-in. Water Pipeline
Project Owner: Logan-Todd Regional Water Commission
Location: Todd County, Kentucky, Montgomery County, Tennessee, and Robertson County, Tennessee
Contractor: Cleary Construction Inc., Tompkinsville, KY
Subcontractors/Suppliers: Down TA Earth Inc. (bore and jack); Core and Main (pipe supplier); McWane Ductile (pipe manufacturer)

The Water System Expansion Project for the Logan-Todd Regional Water Commission, backed by the U.S. Department of Agriculture through a $26.5 million grant as part of its Water and Waste Disposal Loan Program, has been described as the first interstate agreement of its kind between two neighboring states, Kentucky and Tennessee. The cooperative project allowed a water commission located in Guthrie, Kentucky, to supply drinking water to the City of Springfield, Tennessee. It included construction of a 2 million gallon water storage tank and pumping station, an addition to the existing pumping station at the Guthrie plant, as well as the large diameter pipeline it would take to connect it all.

NUCA member Cleary Construction Inc. of Tompkinsville, Kentucky, constructed the Contract 3 – 24-in. Water Pipeline, boasting an almost $10 million price tag. The pipeline stretched nearly 20 miles and consisted of installation of nearly 100,000 lf of 24-in. DIP waterline from the Logan-Todd Regional Water Commission’s treatment plant located in Guthrie, Kentucky, to the Mt. Deason Water Tank located in Springfield, Tennessee. The project also included other appurtenances such as associated valves, fittings, tie-ins, disinfection, testing, bore-and-jack casings, concrete and asphalt paving, site cleanup and restoration, and erosion and sedimentation control generally along US Highway 41 in Todd County, Kentucky, Montgomery County, Tennessee, and Robertson County, Tennessee.

Residents were handled with care and efficiency
Residents were handled with care and efficiency, ensuring that their property was restored to original condition and inconvenienced the least amount possible.

There were several key coordination points of this project that were critical to its success. Due to two other coordinating contracts for a tank and treatment plant that were running concurrently to the line portion, Cleary had to synchronize with the other contracts for the final chlorination of the water line. Due to the length of the project, there were two water municipalities that the project tied in to, and therefore different parties involved. Cleary developed good working relationships with all parties involved.

One of the most difficult tasks was the procurement and scheduling of material. 100,000 lf of pipe required a very large number of deliveries. Coordination and storage of this material was paramount to ensuring a timely and successful project. During the initial material order, Cleary had multiple phone conversations and meetings between its supplier, Core and Main, and the pipe manufacturer, McWane Ductile. Both Core and Main and McWane Ductile noted this was a historic project for them, according to Cleary Construction.

ductile iron pipe
The mass quantity of ductile iron pipe was supplied by Core & Main and manufactured by McWane Ductile.

Another obstacle during the project was installing the pipeline across the Red River. It was determined that a jack and bore would be the most effective method, so Cleary installed approximately 200 lf of 36-in. steel casing under the river. In order to install the bore pits, Cleary had to effectively remove the rock on a steep grade. Cleary did this by the mechanical hoe ram method to avoid blasting near sensitive ecological areas. There were also crossings under the CSX railroad and multiple State Highways.

Cleary Construction Inc. worked with several trusted suppliers and subcontractors on this project. The mass quantity of ductile iron pipe was supplied by Core & Main and manufactured by McWane Ductile. The bore contractor, Down TA Earth Inc. of Science Hill, Kentucky, performed the multiple crossings under roads, railroads and the river.

ductile iron pipe
Cleary hit production goals of up to approximately 3,600 lf feet of the 24-in. ductile iron pipe installed per day.

The Water System Expansion Project supplies 2.3 million gallons of treated water daily to some 14,000 residents of Robertson County, Tennessee. The project was highly publicized in the area due to the impact it would have on the sheer number of residents. Cleary opted to place multiple crews on the project to minimize the amount of time the residents were burdened with construction. Timelines were met when Cleary hit production goals of up to approximately 3,600 lf feet of the 24-in. ductile iron pipe installed per day. Residents were handled with care and efficiency, ensuring that their property was restored to original condition and inconvenienced the least amount possible – The Cleary Way.

“The funding for this project was a loan from USDA Rural Development, which requires lots of oversight from multiple agencies,” wrote Kyle Kenner, System Manager for Logan-Todd Regional Water Commission. “Cleary’s management team did lots of planning and laid out a very detailed attack plan from the start of the project.

“The construction crews they sent to do the work were always ready for the day’s challenges and kept in good communication with LTRWC There were a few things that had to change along the way, just like all projects, but Cleary always had a solution and kept moving forward. Very few change orders were required for the 20-mile long project and it was completed on time.
“If were to do it over again I would strongly recommend Cleary Construction for the job.”

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