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Iron Removal Plant
- August 2025 - Public Well #2 motor controls and the associated SCADA programming are being transferred over to the new Iron Removal Plant on 9/4/2025. The other wells and the Booster Pumping Station changeover are currently being scheduled. It is anticipated to be completed in the next few weeks, with the plant being fully operational at that time.
- July 2025 - The City received approval from EGLE for the Commencement of operation on August 4, 2025. The plant will be tentatively ready to commence operations once the Kirk-Key motor control safeguard is corrected.
- June 2025 - The City is currently awaiting EGLE approval to commission the Iron Removal Plant and working to obtain the certificate of occupancy.
- May 2025 - On May 28, 2025, EGLE conducted an inspection of the new water treatment plant as part of the commissioning and approval process. The site visit was successful. EGLE’s peer review group will now evaluate the water quality parameters collected from the new facility and the current plant. In addition, they will review the hourly/daily water samples gathered during the new plant’s operational period to assess its reliability and water quality performance.
- April 2025 - The Iron Removal Plant has been operating daily for 6 to 7 hours, currently pumping to waste as part of preliminary system verification. During this phase, water quality samples are collected hourly from the Iron Removal Plant and the existing treatment facility to compare key water quality parameters.
- Parameters monitored hourly include:
- pH
- Temperature
- Alkalinity (as CaCO₃)
- Calcium
- Conductivity
- Total Hardness (as CaCO₃)
- Chloride
- Sulfate
- Iron
- Manganese
- Orthophosphate (as P)
- Total Phosphorus
- Free Chlorine
- Total Chlorine
- Dissolved Oxygen
- Oxidation-Reduction Potential (ORP)
- These parameters are closely tracked to ensure the plant's treatment processes are stable and produce water that meets regulatory standards. The City has submitted a request to the Michigan Department of Environment, Great Lakes, and Energy (EGLE) for a Commencement of Operation (COO) visit, proposed for May 23, 2025
- Parameters monitored hourly include:
- March 2025 - The chlorine system has been successfully commissioned and tested. HMO, phosphate, and fluoride pumps have been tested for functionality. New media is also being procured. It is anticipated that the work will be completed by May 6, 2025.
- February 2025 – The top course of the asphalt will be installed in the spring of 2025. The exterior perimeter fencing will be completed by the end of March 2025. RK Davis has a cleanup person on site as needed. The shower room tile, shower accessories, bathroom fixtures, bathroom accessories and lockers are installed per plan. All interior and exterior doors and hardware is installed per specifications. 95% of the signage is also installed. 95% of the interior glass is installed in the window frames. The fire rated glass will be installed within the next 2 weeks. The owner’s contractor has installed interior and exterior security cameras. Fire protection system, HVAC, pressure filters, process pipe pumps and equipment, chemical feed pump and equipment, electrical equipment, generator, controls, misc. and SKADA system are ALL being started up as systems become available throughout the month of March. Engineers and vendor technicians are on site as needed for start-up and commissioning of the various systems. Finial inspections are scheduled as needed along with the checking off items on the substantial completion sheet. Owner training has begun with the various systems with the plant employees.
- January 2025 – MacKenzie Excavation is 99% complete. Restoring the utility parking/ Maintenance area to the west of the water tower. Add crushed concrete to the new parking area. The top course of the asphalt will be installed in the spring of 2025. The exterior perimeter fencing will be installed weather permitting. All exterior and interior doors are installed with the hardware and the permanent keying system. Interior and exterior caulking is in progress and is 60% complete. Fire caulking is 90% complete. All the removable steel galvanized grating is complete in the Process Area, Pipe Gallery and the Pump Room. The epoxy floor coatings are 95% complete and the rooms that require clear sealer are 75% complete. All rough in inspections have been complete and approved per the city and local township inspectors. The building is now being heated on the permanent natural gas supply. The building electrical system is ongoing and is 95% complete. The SKADA system contractor has been on site performing their related work and will be on site off and on in February and March as required performing start-up on equipment.
- December 2024 – Mackenzie Excavation is 99% complete. The top course of the asphalt will be installed in the spring of 2025. The perimeter roof cap flashing at the Pump room is installed. The standing seam roof and accessories are 99% complete. Exterior doors, interior doors, exterior windows are installed. The galvanized steel grating is installed at the Pipe Gallery and the Pump room. The remainder of painting is 95% complete. All rough inspections have been completed and approved. The added Carbon Monoxide Detector is still being discussed with the Building inspectors office. The HVAC system is ready to be turned on as the permanent power has been energized to the electrical panels. The domestic water service is turned on to the building. The process pipe, chemical pipe feeds, pumps, valves, HMO equipment, Chlorine equipment and all other equipment is 97% complete. The media is installed 100% in two of the large pressure tanks. The third tank has 50% of the media installed. The pipe insulation is 75% complete and is continuing to be installed. Electrical wire pull is 85% complete. The SCADA control system for the building has started and is continuing. All other trades are scheduled as needed to complete their related work.
- November 2024 – MacKenzie Excavation has placed the on-site topsoil per the plan but needs to touch up disturbed areas from construction equipment driving thru it. Backfill the two riser pipes at the aeration basins in 2 weeks after the insulation is installed. The metal roof is 100% complete just the East downspouts need to be installed after the stored Media material is moved. Mid December. Exterior doors are installed. The overhead doors are installed. The perimeter roof flashing at the membrane roof at the pump room will be install mid-December. The galvanized steel grating at the Pipe gallery is complete. Painting of interior wall and ceiling surfaces are 95% complete. Office 116 and Lab 115 above ceiling work is 95% complete. The drywall hard lid in the bathroom area will be installed mid-December. All rough inspections are approved as of today. 90% of all doors and hardware is installed. Domestic water service is turned on to the building and the leak test passed per the Fishbeck Specifications. The leak test for the boiler pipe is being performed this week. Domestic water pipe is 95% complete. Process pipe, chemical pipe feeds, pumps, valves and misc. equipment are 85% complete. Pipe insulation is 2% complete. The placement of the Media in the three pressure tanks is 35% complete. Electrical testing of the Buckets and breakers have started today. The electrical contractor is installing lights, devices, disconnect boxes, control boxes, surface conduit, pulling heavy and light gauge wire and all other work required.
- October 2024 - Mackenzie Excavation is complete with all the underground pipe installation. The gravel drive is installed along the EQ Tank per plan and compacted. The stone Maintenance strip at the West side of the building is 85% complete. The drainage swale at the West side of the site is complete. The placement of the topsoil is 50% complete. The existing asphalt was milled and hauled away by Rieth Riley and the entire base asphalt is installed per the plan. The top wearing course will be placed in the spring of 2025. Seeding of the site will also take place in the spring of 2025. The cabinets in laboratory Room 115 are installed. The ceiling grid is 100% complete in Laboratory 115 and the Office 116. The epoxy floor is 100% complete in the Laboratory 115 and in the Office 116. he standing seam metal roof is 100% complete along with the gutter and downspouts. All exterior and interior concrete is installed except a proposed exterior concrete curb at the Pump Room 118 by the pipe bollards for water drainage. The interior and exterior painting of all three Pressure Tanks is complete. The flat membrane roof is installed at the Pump Room 118. The miscellaneous steel contractor is 80% complete. The last steel item remaining is the Pipe Gallery grating which has been cut and fitted and sent out to be Hot dipped Galvanized. The overhead doors are installed per the plan. 99% complete. Traverse City Glass is 90% complete with interior and exterior frames, doors, hardware, window frames and glass. FHC HVAC duct, louvers, exhaust fans and equipment are 85% complete. FHC fire protection is 80% complete. Process piping and domestic plumbing is continuing in all areas.( 75% complete ). The Pressure tanks media installation and backwash is 50% complete. media installation is continuing. The two exterior Aerators are installed. Interior Blowers, chem feed equipment, air compressor, tow boilers, water heater, HNO tanks, weighing scales are all installed and being hooked up. The Electrical contractor scope of work; . All MCC panels are in place and heavy wire is pulled in from the main exterior transformer but are not yet terminated. The new main power pole at Saginaw highway and new transformer is installed.
September 2024 – Mackenzie Excavation prepped and graded out the north overhead door apron, graded the area west of the pressure tanks for exterior concrete slab. RK Davis poured various, remaining slabs needed to finish installs. The Traffic coating is installed on the Aeration Basin slab. The aluminum handrail is installed around the perimeter of the EQ tank along with the ladder down to the bottom. The Membrane roof is installed at the pump room, skylights and perimeter flashing needs to be installed. Interior metal ceiling stud framing is 98% complete. All drywall ceilings are 98% complete and installed per fire code. Painting of the walls and ceilings are 95% complete. The steel I-beams are installed in the pipe gallery for the grating. Exterior aluminum doors are 25% complete. Interior aluminum fire rated frames with glass are 75% installed. Interior Equipment pads coatings are 95% complete. The HVAC duct at the Equipment platform is 75% complete. The remaining duct at the ground floor is 80% complete. Process piping at the interior pressure tanks is 99% complete. Interior overhead copper piping is 70% complete. Interior pipe manifolds and related accessories in all three Pressure Tanks is 80% complete. The pump room piping is 80% complete. Various pumps and process equipment are installed in the Chemical rooms. This work is about 50% complete. The primary high voltage tie in connection along Saginaw Highway along with the new utility pole is installed. The underground gas line is installed up to the new building at the east side wall along with the new gas meter. Interior surface mount conduit is 75% complete. September 2024 – Mackenzie Excavation prepped and graded out the north overhead door apron, graded the area west of the pressure tanks for exterior concrete slab. RK Davis poured various, remaining slabs needed to finish installs. The Traffic coating is installed on the Aeration Basin slab. The aluminum handrail is installed around the perimeter of the EQ tank along with the ladder down to the bottom. The Membrane roof is installed at the pump room, skylights and perimeter flashing needs to be installed. Interior metal ceiling stud framing is 98% complete. All drywall ceilings are 98% complete and installed per fire code. Painting of the walls and ceilings are 95% complete. The steel I-beams are installed in the pipe gallery for the grating. Exterior aluminum doors are 25% complete. Interior aluminum fire rated frames with glass are 75% installed. Interior Equipment pads coatings are 95% complete. The HVAC duct at the Equipment platform is 75% complete. The remaining duct at the ground floor is 80% complete. Process piping at the interior pressure tanks is 99% complete. Interior overhead copper piping is 70% complete. Interior pipe manifolds and related accessories in all three Pressure Tanks is 80% complete. The pump room piping is 80% complete. Various pumps and process equipment are installed in the Chemical rooms. This work is about 50% complete. The primary high voltage tie in connection along Saginaw Highway along with the new utility pole is installed. The underground gas line is installed up to the new building at the east side wall along with the new gas meter. Interior surface mount conduit is 75% complete. September 2024 – Mackenzie Excavation prepped and graded out the north overhead door apron, graded the area west of the pressure tanks for exterior concrete slab. RK Davis poured various, remaining slabs needed to finish installs. The Traffic coating is installed on the Aeration Basin slab. The aluminum handrail is installed around the perimeter of the EQ tank along with the ladder down to the bottom. The Membrane roof is installed at the pump room, skylights and perimeter flashing needs to be installed. Interior metal ceiling stud framing is 98% complete. All drywall ceilings are 98% complete and installed per fire code. Painting of the walls and ceilings are 95% complete. The steel I-beams are installed in the pipe gallery for the grating. Exterior aluminum doors are 25% complete. Interior aluminum fire rated frames with glass are 75% installed. Interior Equipment pads coatings are 95% complete. The HVAC duct at the Equipment platform is 75% complete. The remaining duct at the ground floor is 80% complete. Process piping at the interior pressure tanks is 99% complete. Interior overhead copper piping is 70% complete. Interior pipe manifolds and related accessories in all three Pressure Tanks is 80% complete. The pump room piping is 80% complete. Various pumps and process equipment are installed in the Chemical rooms. This work is about 50% complete. The primary high voltage tie in connection along Saginaw Highway along with the new utility pole is installed. The underground gas line is installed up to the new building at the east side wall along with the new gas meter. Interior surface mount conduit is 75% complete.
- August 2024 – Mackenzie Excavation has installed the remaining two fire hydrants along with the underground process pipe and sewer pipe. They are 97% complete with their related work. The underground 16” Backwash pipe, 16” Overflow pipe and the two 16” sanitary sewer pipes have all been installed at the EQ tank. The underground 12”x 10” live tap, test pipes/ flush out pipes have been removed and the permanent connection has been made between the flanges and backfill and compacted per the specifications. The gravel placement for the new asphalt is 85% complete. The attic hatch is installed. Window frames and the glazing are installed, 97% complete. Drywall ceilings are 95% complete. Interior painting is 60% complete. Fire suppression field measurements are complete. Domestic rough in plumbing is 80% complete. The interior water service manifold is 97% complete. HVAC installation is 50% complete. The larger Process pipe installation is 95% complete in the pipe gallery, all other Process pipe is only 15% complete. Electrical surface mount conduit and junction boxes rough-in is 40% complete. All rough-in inspections with the local code Inspectors have been completed and approved. August 2024 – Mackenzie Excavation has installed the remaining two fire hydrants along with the underground process pipe and sewer pipe. They are 97% complete with their related work. The underground 16” Backwash pipe, 16” Overflow pipe and the two 16” sanitary sewer pipes have all been installed at the EQ tank. The underground 12”x 10” live tap, test pipes/ flush out pipes have been removed and the permanent connection has been made between the flanges and backfill and compacted per the specifications. The gravel placement for the new asphalt is 85% complete. The attic hatch is installed. Window frames and the glazing are installed, 97% complete. Drywall ceilings are 95% complete. Interior painting is 60% complete. Fire suppression field measurements are complete. Domestic rough in plumbing is 80% complete. The interior water service manifold is 97% complete. HVAC installation is 50% complete. The larger Process pipe installation is 95% complete in the pipe gallery, all other Process pipe is only 15% complete. Electrical surface mount conduit and junction boxes rough-in is 40% complete. All rough-in inspections with the local code Inspectors have been completed and approved.
- July 2024 - Asphalt Prep and grading is 95% complete. The City of Grand ledge will be installing the paving. The underground gas line will need to be installed up to the building before and the EQ tank sheeting removal and backfill will need to be complete the paving is placed. Exterior concrete slabs are 90% complete. The remaining concrete is the North overhead door apron and the remaining concrete slab to the pressure tank area. The EQ tank concrete walls are 100% complete. All the underground pipe, fittings and accessories are on site for the underground tie in at the EQ Tank. The interior and exterior masonry is complete. Interior misc. steel for the Equipment platform railing, stairs, and pipe gallery support steel is installed. The wood Nailer is installed at the Pump Room Roof. The exterior stud framing for the clerestory wall is installed and covered with plastic sheathing for weather protection. The interior ceiling metal stud framing is 85% complete along with the vapor barrier. The sloped roof ice & water shield protection is installed correctly along with the rake trim and eave trim per the specifications. Interior rough in domestic water lines are 80% complete. HVAC is 15% complete. ductwork to be installed after the drywall ceiling is completed. Process piping is 80% complete. The new generator is installed along with the primary and secondary underground wire out to the transformer by the Saginaw highway. Interior electrical is 5% complete.
- June 2024 – The east side of the roof has been completed with an ice and water shield. Pipe gallery from the steel support structure has been installed. The HVAC installation continues from the mechanical platform. An asphalt patch over the entrance gate was poured. Masonry was roughed-in and completed in the bathroom and shower areas. Exterior pipe bollards at the pump room were poured. Installing the metal studs and the Dense glass fiber board at the Clerestory wall at the roof peak was completed.
- May 2024 - The interior concrete floors are 100% complete along with all the saw-cut control joints. The gravel base is graded and is ready to receive the asphalt base course. Site grading is complete along Saginaw Highway at the new 12” underground Raw-Water service. The EQ Tank rebar steel and wall panels are 99% complete. Exterior concrete slab is poured at the Pressure tanks. The concrete topping is poured at the Equipment Mezzanine platform along with the Pump room roof concrete topping. The 4” masonry block veneer is 90% complete along with the exterior door frames. The exterior block veneer washing is 60% complete. The metal roof decking is 75% complete and is being detailed before the OSB underlayment can be installed. The Galvanized steel support framing in the pipe Gallery is 90% complete. The trench drain gratings are installed in the Process Area Room. The three large exterior Pressure Filters are set into position and related valves, tees, spool pipes and accessories are being installed. Approximately 35% complete with the filter piping. The underground water main tap is installed and valve boxes are installed along with as-built locations marked up on the jobsite plan. All underground water pipes have been pressure tested and witnessed and passed per the Fishbeck specifications. All underground water pipe has been disinfected and passed the Bacteria test per the City testing standards. The medium Voltage switchgear is on site for the electrical distribution along Saginaw Highway.
- April 2024 - Concrete forms are removed in EQ tank area. Truss work continues and bracing in the process area. Work commences on precast ceiling planks and steel roof supports. Masonry continues on the process area and water proofing, and block veneer installation. Building scaffolding, and infilling the knockout filter wall and the 8" wall at pump room. Concrete testing and pouring trench drains in various building rooms, as well as work on west wall ramping up.
- March 2024 - Concrete work on EQ tank, sump pits, aeration basin, and rooms. Installation of partial trusses to allow for masonry work. Underground trenching for processing pipes and conduit continues. Masonry work continues on building structure and work on individual rooms within the building.
- February 2024 - Poured concrete at the east wall of the Aeration building foundation. Stripped wall panels at the process area. Poured the small section of footing wall in the Laboratory area. Installed the 6” underground Sanitary line for the IRP. Masonry continues on the Laboratory. Conduit was installed for office rooms at the IRP.
- January 2024 - Continue tying steel and setting forms. Finish setting sleeves in the Pipe Gallery walls and in the top of Detention Basin, and form the top hatch. Continue running conduit to process area. Work continues on sheet pilings around the EQ tank. Preparation for the 6" sanitary line began. Block laying at the ICB was finished.
- December 2023 - Concrete work begins on many interior areas, including electrical work.
- November 2023 - Forms are erected and footing walls are poured for exterior building walls. Material staging for sanitary sewers and water main. Waterproofing of tanks and basins in completed. Insulation boards installed on buildings. Work on the interior of the building continues (forms and footings for chemical tanks, office areas, etc.). Electrical work and laying conduit continues. Backfilling and compaction of exterior and interior areas begins.
- October 2023 - Began testing and filling basins and tanks. Work continues on the chemical rooms and excavation for conduit. Site work for new driveway to Well #6. Many in storm ducts and manholes installed on site. Started and finished masonry for the Equipment Platform.
- September 2023 - Walls are poured on the Iron Control building and piping is installed. Forms are erected and concrete is poured for the Wet Well. A significant amount of trench work is complete and conduit is installed, as well as electrical paneling. Masonry on the chemical rooms begins.
- August 2023 - Work on the wall mats continue. The foundation for the chemical rooms in the Iron Control building is constructed. Electricians onsite for staging and continued on to install electrical for Iron Control building. Walls are poured.
- July 2023 - Steel wall mats are erected for the Iron Control building.
- June 2023 - Work continued to prepare steel framework for the Detention Basins and work on the South retention wall.
- May 2023 - Site work and prepping for the IRP foundation
- April 2023 - IRP Construction Breaks Ground
- December 13, 2022 - Bid Awarded to RK Davis for Construction
- November 8, 2022 - Request for IRP Construction Proposals
- May 24, 2022 - Final IRP Project Plan approved by Council
PROJECT HISTORY & SUMMARY
Beginning in 2018, the existing Iron Removal Plant (IRP) that treats our City water supply began to near the end of its useful life. Through numerous presentations, research, cost comparisons, and public input, City Council debated the option to replace the Iron Removal Plant, the cost of connecting to the Lansing Board of Water and Light, the ability to include water softening in the future, the potential changes to water softening options over time, and the possibility of a City “preferred vendor” arrangement for home-based water softening systems.
On November 23, 2020, City Council moved to replace the IRP, which would be designed to add water softening in the future, if determined. To view a timeline of City Council action, bids, resolutions, and research, click here.
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