A food manufacturing client chose Haskell to expand and renovate to create a Water Resource Recovery Facility.

How do you convert an existing pretreatment facility into a Water Resource Recovery Facility? This food-focused client called on Haskell to answer this very question. The facility, which recycles and reuses wastewater to minimize discharge, was built in multiple phases to treat wastewater and reincorporate a portion for production. This method is often associated with lower investment costs and energy use.

For this project, where time was of the essence, Haskell relied on its in-house capabilities to get the job done quickly. Leveraging Haskell Steel to fabricate all the building’s structural steel saved time and kept the design flexible.

Three treatment systems combined to form a powerhouse for water recycling.

To visualize the primary treatment system, Haskell created a 3D model of the existing dissolved air flotation (DAF) system and the proposed changes that would convert it into suspended air flotation units (SAF). The SAF system differed in removing over 90% of total suspended solids, using only 20% of the energy that DAF uses, thereby reducing operational costs. Field staff referred to the 3D model to coordinate installation, and the final product closely matched the initial renderings. The facility’s equalization system was also upgraded. The new system, which consists of a 400,000-gallon calamity tank and diversion system, added volume to homogenize the influent waste stream and mitigate shock-load events.

The design and construction of a 27,000-square-foot building housing secondary solids removal and dewatering systems marked the secondary treatment system. This system produces process effluent suitable for utility water and further treatment at the water center. New aeration basins were added, increasing capacity by 350%.

Another building, this one 12,000 square feet, was added to house the tertiary treatment system. The water purification equipment includes carbon filtration, disinfection equipment and reverse osmosis units.

Haskell consolidated project phases and maximized savings.

While this project was initially planned in 13 phases, the Haskell team consolidated it into four main phases focused on the project’s true priorities. Instead of replacing an underperforming anaerobic treatment digester, Haskell and the client focused on expanding aerobic treatment capacity, saving $15 million. After returning savings to the client, the project’s final contract value was reduced by $1 million. Haskell’s integrated and progressive design-build approach allowed direct and constant contact between the design, construction and commissioning teams, resulting in an efficient and fast-tracked project.