Western Monmouth Utilities Authority (WMUA) in Manalapan, N.J., operates more than 30 pump stations and services more than 79,000 customers. Operating at this capacity with stations surpassing 40 years old wasn't cutting it. It was time to make them more efficient, aesthetically appealing and safe.
The initial five sites to be overhauled were chosen so safety issues and outdated equipment could be addressed first. Two of the sites had wet well-mounted pump stations with no buildings. The controls were in cabinets exposed to the weather, posing a serious safety hazard to employees when working on them in foul weather.
The other three stations were cinder block buildings that housed the controls for the pumps, an emergency generator and the dry well for the pumps, accessible only by ladder. The authority upgraded to submersible pumps in the old wet wells, so the former building locations had to be moved to accommodate the new technology. The new buildings now house all the controls, and even includes bathroom for employees.
Oldcastle Infrastructure, A CRH Company, was selected for their Easi-Set brand of prefabricated buildings that offer speed of installation as well as the many aesthetic options available. The two new wet well buildings are Easi-Set R-10 insulated buildings, and the three dry well pump stations are Easi-Set model 12-ft-by-16-ft R-10 insulated buildings.
All five buildings have a modular wooden truss roof and fiberglass shingle roof coverings installed over the precast roof system, as well as a manufactured stone veneer exterior. The upper section of the insulated precast sidewall is a simulated lapboard siding created with textured form liner material. All doors, hardware and louver dampers were installed in the buildings prior to delivery.
“The aesthetic appeal with the options available on the Easi-Set buildings is what convinced the owner to go with these particular buildings. The look of siding and cultured stone was desired to blend in with the residential neighborhoods these pump stations are located in. The precast concrete provides the owner with low maintenance and durability. For us, as the contractor, it improves scheduling by allowing for a one-day install of the precast rather than the time consumed with forming rebar, pouring concrete and cure times. This allows subsequent work such as plumbing, electrical and piping to begin immediately, which may save several weeks or more per site.”
—David Beesley, project manager for Coppola Services.
While Coppola Services was constructing the underground structures on-site, personnel from Oldcastle Infrastructure poured and prepped the building, cutting weeks out of the project schedule. Because each building was set on-site, other trades could quickly move ahead with their work. The final building was delivered in May, with WMUA already planning to renovate and upgrade another pump station using an Easi-Set building.