Solutions to Help Accelerate Pump Station Construction Schedules
By Kurtis DeShaw, PE – Have you ever been up against a wall with your water distribution system? Has your pump station reached, or even gone beyond maximum capacity? Do you find yourself scrambling to keep up with new developments? If you’re experiencing any of these scenarios, chances are your current pump station might be at the end of its lifecycle and you need to plan for a new one. With all the problems you’re experiencing, you needed that new pump station yesterday.
To help facilitate schedules while meeting various needs with future improvements, sometimes you need to explore alternatives. Fortunately, there are three options available to help construct your new facility and get it up and running within your scheduled constraints—a pre-packaged station, a pre-packaged skid inside a built-in-place building, or a custom built-in-place pump station.
While the selected pump station construction method will dictate what kinds of customizations are available and drive the construction schedule itself, each of the following solutions have unique construction methodologies, construction sequencing, and scheduling impacts.
1. Pre-Packaged Station
Pre-packaged stations come as complete units including the building, piping, and electrical. The contractor installs the suction and discharge transmission piping and pours the foundation. Once the piping and foundation is complete, the contractor sets the pre-packaged station on a foundation, makes the required electrical and piping connections, and the station can be operational within a few days. This method offers the shortest timeline from beginning of construction to production readiness.
These days, the customization of pre-packaged stations has improved. You can now link buildings together to increase size, add cranes, and customize the exterior to match existing buildings. One of the primary benefits of this approach is that pre-packaged manufacturers are highly specialized in pump station design and construction which gives end users an up-to-date solution with a shorter timeline to completion.
This solution has:
- The shortest construction timeline (but remember to be cognizant of the production timeline, which can be in the 3-12+ month range depending on market volatility).
- The lowest price tag.
2. Pre-Packaged Skid Inside a Built-In-Place Building
With this solution, the piping, valves, pumps, and flow meters come installed on a pre-packaged skid and are set in a built-in-place building (see photo below). This allows the electrical to be pre-packaged and on the same or a separate skid depending on your preference. The built-in-place building design can be modified to include a sample area, bathroom, or any other customization you need. However, due to the complexity of the building, the construction process is much longer and the timeline from setting the pre-packaged skid to becoming fully operational is significantly longer.
This solution has:
- Longer construction timelines.
- More building customizations and options, such as bathrooms.
- A wide range in price from middle- to upper-tier options.
3. Custom Built-In-Place Pump Station
For those with special circumstances or requirements, everything in a custom built-in-place pump station is fully customizable. Keep in mind that this method can present more issues with work quality if your contractors are working outside their level of expertise. The process from beginning of construction to fully operational is also the longest of these three approaches.
This solution is:
- The most customizable.
- The most time-intensive to construct.
- The most expensive.
Selecting the Right Construction Method for Your Project
The primary driver for selecting a pump station construction method is to choose a method that meets your needs, budget, and schedule. While customization has vastly improved in pre-packaged stations, it is still easier to address certain requests by using a built-in-place solution. Project budgets and schedules vary significantly depending on the chosen method and underscores the importance choosing the right way to construct your new pump station.
The method of construction also has a significant impact on schedule and the finished product. Listening to your owner’s staff requirements is a great place to start to help determine what direction to go in terms of construction.
Since selecting the right pump station method is dependent upon various factors, it’s important to walk through the different considerations regarding customization, budget, and schedule to find a construction method that fits your needs. If you need a pump station evaluation or have questions about pump station construction, please contact me at any time with questions.
Kurtis DeShaw, PE., is a senior water-wastewater engineer and serves as the Billings office’s Water-Wastewater Group Office Market Leader. He specializes in system hydraulics, modeling, pump stations, lift stations, troubleshooting, and water and sewer rehabilitation projects. Contact him at kdeshaw@m-m.net.
Technical review of this article provided by Casey Hanson, PE.
