Civil

Cerrudo Services recently completed a $3,100,000 underground electrical upgrade project at Military Ocean Terminal in Concord, CA. Cerrudo completed the first civil works design build contract managed by the San Francisco District Corps of Engineers, a $2,800,000 wetlands restoration project. Our overall performance rating was “Outstanding”.

ADVANCED DEVELOPMENT LIQUID COOLING LOOP – LAWRENCE LIVERMORE NATIONAL LABORATORY

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  • Client: Lawrence Livermore National Laboratory
  • Location: Livermore, CA
  • Date: 2016
  • Contract #: B617293
  • Value: $868,959

Project Details

Building 453 developed a need to increase the flexibility of liquid cooling for advanced development computers planned in the future. This new computing is anticipated to have a greater heat load than what is currently available in the building.  Cerrudo Services provided new underground low conductivity water (LCW) supply and return piping from LLNL’s existing underground supply and return piping into Building 453, requiring approximately 600 LF of trenching.

Work occurred adjacent to Haussmann Lake. During mobilization Cerrudo erected approximately 600 LF of special exclusion fencing around the work area to keep endangered red legged frogs from migrating into the work site and the trench.  Pipe materials were received and the proposed pipeline trench surveyed.  Asphalt paving was removed then potholing was conducted to locate existing utility lines.

After identification and marking of existing utilities, excavation of the five foot deep trench proceeded from the (east) building end towards the (west) existing LCW pipe connection location. Sand bedding was placed, then 12” diameter Aquatherm polypropylene supply and return pipes were placed over the bedding.  Each 40 foot pipe section was connected by heat fusion. Tracer wire was installed on top of the pipes.  The trench was backfilled and compacted, then a five inch thick concrete slurry cover was poured over the backfill.

At the building, the two pipes penetrated the exterior metal-panel wall, through an eight foot plenum space, then into the interior of the building through an existing damper location that was demolished and infilled. Since no construction dust created from the installation of the pipes was permitted to escape to the plenum, containment was constructed to seal off the plenum area from the work area.  Pilot holes were drilled in the exterior wall to confirm stud spacing and absence of wall utilities, then holes were cut into the façade and pipes installed through the building envelope.

At the existing 18” LCW pipe location, approximately five feet below grade, the site was excavated and a 8’ x 4’ x 4’ pre-cast concrete vault installed over a level gravel bed. The pipes coming from the building were run into the east side of the vault.  After shutting off and draining the water from the existing 18” supply and return piping, those pipes were cut, custom tee’s installed and new 12” pipe fused to the tees and brought into the vault to connect to the pipe coming from the building side.  After all connections were made, the vault was backfilled.

After pressure testing the pipe, new asphalt paving was installed over the concrete slurry and the site restored.

ELECTRICAL UPGRADES AT MILITARY OCEAN TERMINAL CONCORD (MOTCO)

  • Client: US Army Corps of Engineers
  • Location: Concord, CA
  • Date: 2015
  • Contract #: W941238-11-D-0031-0002
  • Value: $3,134,594

Project Details

Cerrudo Services, Inc. designed and constructed the electrical upgrades for the military ammunition distribution post Military Ocean Terminal Concord (MOTCO).  MOTCO’s mission is to receive ammunition from ships at piers on the Sacramento River and distribute the ammunition to various Army posts via rail.

The project scope of work consisted of five parts:  1) upgrade of the PG&E Bay Point Feed substation; 2) upgrade of Pier 3 electrical distribution; 3) replace pole type transformers with pad mount transformers; 4) replace overhead power and communication distribution with a new underground system; and 5) provide pad-mounted primary voltage switches/junction boxes on 5 KV circuit along a section of White Road.

The design included electrical design drawings, calculations and specifications.  Design elements included calculations for electrical load, roadway lighting foot candles, voltage drop and arc flash.  Brokaw provided a layout for underground alignment indicating trenching population and location of underground structures, typical trench cross-sections, utility conflicts, and placement of hand holes and vaults.  Replacement requirements of Bay Point Feed fuse cut-outs were developed.  Layouts were provided for pole to underground transition at riser locations, pad mounted transformer and primary sectionalizing switch equipment and secondary service panel replacement.  Single line diagrams for electrical, telecom and signal distribution systems were provided.

There was a “moderate to high” risk of encountering MEC (munitions and explosives of concern) in the area of underground work.  Once the alignment was approved, the installation of underground work began.  The UXO (unexploded ordnance) team was on-site to provide UXO construction support during excavation and backfill operations.  The trench alignment was marked and staked.  After trenching, PVC conduit supports were installed for the high voltage duct bank locations.  After low voltage conduits were installed, the trench was backfilled and compacted.  After inspection and approval of the high voltage duct bank conduit installation, concrete was poured around duct bank conduits.  Once the concrete had cured, the trench was backfilled to the top of the existing grade.

After the conduits were in place, underground conductor was pulled for the primary power, fiber optic, telecommunications and CATV systems.  This work included pulling new conductor into the underground conduit, constructing pads for new transformers and switches, installation and testing of new equipment and panels and connections for all of the systems.  We coordinated with PG&E to upgrade the new Bay Point Feed by installation of a new pole top air switch on an existing pole.

Cerrudo upgraded the electrical distribution at Piers 3 and 4 with a new dry type pad mounted transformer installed in the same location as the demolished transformers at buildings A-22 and A-23.  New 800 amp panel boards at buildings A-22 and A-23 were installed.  We installed a new secondary feeder conduit and conductor between the new transformers and panel boards were installed, and terminated and energized existing circuits to new panel boards.  Pads were constructed and new transformers installed at four locations, connected to existing primary and secondary feeders.  Four new fused pad mounted switches along the White Road primary feeders were installed.  Work included new pads, cutting into the existing duct bank and conductor and installation of the switches.  New underground primary power wiring and equipment were provided to replace the demolished overhead system.

US COAST GUARD TRAINING CENTER – CDC PLAYGROUND

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  • Client: US Coast Guard
  • Location: Petaluma, CA
  • Date: 2014
  • Contract #: HSCG88-14-J-PFP443
  • Value: $594,567

Project Details

Cerrudo Services designed and constructed a new playground for the Child Development Center.  The existing playground on the site was inadequate for the age groups serviced, did not meet accessibility requirements and did not meet USCG Child Day Care regulations.  Cerrudo was tasked with providing the design and construction of a separate fenced play yard for three age groups:  infants/toddlers, pre-school (2-3 years old) and pre-kindergarten (3-5 years old).

The infant/toddler area is located at the lower end of the playground directly adjacent to the building.  It contains a small play structure and sand play area with a shade sail covering.  The pre-school area is located toward the center of the playground, with a play structure and sand play area.  The upper area of the playground contains the pre-kindergarten play structure and sand area.  Each play area received poured in place resilient safety surfacing.  The connecting paths are concrete, and the areas between each grouping are sodded.  Irrigation for the sod was provided.  There is a small setting for picnic tables and a small vegetable garden area at the upper corner of the playground.  Each play area is separated by a four foot fence, and the perimeter of the playground is protected by a six foot fence.

                

HAMILTON WETLANDS RESTORATION PIPELINE MARSH CROSSING

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  • Client: U.S. Army Corps of Engineers, San Francisco District
  • Location: Novato, CA
  • Date: 2002
  • Contract #: DACW07-02-C-0003
  • Value: $1,268,074

Project Details

Cerrudo Services furnished and installed approximately 1,600 lineal feet of 30 inch diameter steel pipeline across the former Hamilton Army Airfield outboard marsh. The pipe is supported 18 inches above the existing ground with pre-cast concrete block saddle supports and runs 300 feet inside the levee through the tidal marsh to 300 feet off shore into San Pablo Bay.

The pipe is a segment of the dredged fill material pipeline required to transport dredged material to the Hamilton Wetland Restoration Project. The Wetlands project has restored approximately 1,000 acres of former Hamilton Army Airfield to tidal and seasonal wetlands. Dredged material totaling 10.6 million cubic yards has been pumped through the pipeline and placed at the site.

US COAST GUARD SAN PEDRO ROADS AND PARKING PAVING REPAIR

  • Client: US Coast Guard
  • Location: San Pedro, CA
  • Date: 2009
  • Contract #: HSCG88-09-J-623196
  • Value: $444,100

Project Details

Cerrudo Services rehabilitated roads and parking areas located at BSU San Pedro.  Work included removal of existing asphalt, preparation of the base layer, installation of new asphalt, compacting operations, striping new asphalt parking lots and roads, and slurry coating.

Cerrudo scarified, cleaned and prepared existing asphalt pavement at four separate locations on the base, overlayed with 3,200 square yards of 2” asphalt concrete.  Potholes were patched and a slurry seal was put down.  A new parking lot with 10,000 square yards of asphalt surfacing was paved.  A total of 265 parking spaces were striped and concrete parking stops installed.

The project affected all personnel arriving and leaving the BSU San Pedro complex.  The project affected 65% of the roadways and parking areas on the base, and required the main entrance to the base to be relocated to a secondary back up gate.

Several hidden conditions were encountered that required resolution.  A 4,000 SF concrete slab was discovered 2” below the parking lot surface.  Work was redirected to other areas in order to stay on schedule.


INBOARD BRAC REMEDIAL ACTIONS

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  • Client: US Army Corps of Engineers
  • Location: Novato, CA
  • Date: 2008
  • Contract #: W91238-04-C-0033
  • Value: $1,801,886

Project Details

Cerrudo Services conducted Base Realignment and Cleanup (BRAC) remedial actions inboard of the bay front levee at the former Hamilton Army Airfield, Novato, California.

Cerrudo Services excavated soil contaminated with DDT, heavy metals and petroleum hydrocarbons from eight remote locations.  Excavations ranged from six inches to over 10 feet in depth with areas extending a few square feet to over an acre.

Cerrudo excavated, stockpiled and characterized for disposal 13,446 cubic yards of contaminated soil.  The stockpiles were divided into 100 cubic yard grids and discrete samples were taken for each grid.  Discrete samples were analyzed to more specifically identify the Class I waste and as a result reduced the overall cost of disposal.  Cerrudo loaded, weighed, transported and disposed of 17,380 tons of waste to approved landfills.

All work was conducted from the inboard side of the levee because of ecological considerations regarding coastal salt marsh habitat.  Tidal and wave action creating a breach was another consideration because one area of contamination was well within the outboard half of the levee. Excavation into the levee was conducted during a low tidal cycle and required immediate backfill and backstopping so that the levee could be later repaired to new construction design specifications.

 

HAMILTON FIELD FLOOD PROTECTION LEVEE

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  • Client: City of Novato
  • Location: Novato, CA
  • Date: 2007
  • Contract #: 00-013
  • Value: $1,466,606

Project Details

Cerrudo Services raised an existing wave wall and levee at Hamilton Army Airfield.  The levee and wall are located between the airfield and the local residential neighborhood.  The goal of the project was to increase protection from high water during the Airfield’s transformation to a natural wetlands.

A majority of the work consisted of raising the existing levee from two to four feet high.  Onsite borrow material was placed on the existing levee with scrapers.  The soil was then graded and compacted to the specified percentages.  Approximately 30,000 cubic yards of borrow material were used to raise the levee.  A total of 6,200 lineal feet of concrete block wall was raised two to four feet depending on pre-existing conditions.  Cerrudo was required to screen out debris as well as rocks and cobbles that were too large to include in the final earthen wall.

 

                

HAMILTON WETLANDS RESTORATION DESIGN BUILD

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  • Client: US Army Corps of Engineers
  • Location: Novato, CA
  • Date: 2007
  • Contract #: W912P7-05-C-0011
  • Value: $3,133,289

Project Details

Cerrudo Services designed and constructed of a portion of the Hamilton Wetlands Restoration Project, responsible for design of a 9 foot high, 6,600 LF Wildlife Corridor Berm with a 16 foot wide aggregate crown road, a Panne Berm, five Intertidal Berms and a Settling Basin.

Construction activities required relocation and grading of approximately 76,000 CY of contaminated soil, prior to construction of the Wildlife Corridor Berm.  The berm construction utilized fill material from on site borrow areas that was excavated and transported for placement.  Total compacted clay fill exceeded 111,000 cubic yards in the berm structure.

Demolition of four runway concrete revetments and over one thousand LF feet of taxi way was also part of the contract.  Challenges included coordination of the interaction between the design group and the review group.  An additional challenge was conducting construction activities during what turned out to be the wettest December in Marin County in the last 50 years.

BEL MARIN KEYS PARCEL FIVE LEVEE REPAIR

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  • Client: California State Coastal Conservancy
  • Location: Novato, CA
  • Date: 2007
  • Contract #: 06-026
  • Value: $418,830

Project Details

Cerrudo Services repaired approximately 6,800 feet of damaged levees along San Pablo Bay and Novato Creek protecting farm land owned by the State Coastal Conservancy known as Bel Marin Keys Parcel Five.

Access roads were created and maintained throughout construction.  Construction was conducted in adverse weather conditions and impending breech conditions.  Undesirable material was stripped from the levee and on site borrow material was excavated and benched into the existing structure.  Erosion protection of rip rap on geotextile material was installed with long reach excavators on areas that experience the greatest wave action.

US COAST GUARD TRAINING STATION – H COMPLEX SITE DRAINAGE REPAIR

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  • Client: US Coast Guard
  • Location: Petaluma, CA
  • Date: 2006
  • Contract #: HSCG88-06-J-6L3002
  • Value: $70,414

Project Details

Cerrudo Services replaced French drains and facilitated drainage away from the buildings with a custom swale, adding drain inlets and cleanouts as required.  Custom flashing, gutters and downspouts were manufactured and installed to divert roof runoff away from the buildings.  Numerous below ground utilities required innovative rerouting of the drain pipes.  All work was completed without damage to these utilities.