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The Challenge

Bluegrass Engineering was selected to be the design team behind the Design-Build contract with Luttrell & Sons Construction from Dundee, Kentucky to supply a design to replace the failed domestic WWTP at the Aleris Aluminum facility east of the City of Lewisport. The project included approximately 1,000 LF of 8-inch gravity sewer, 16,000 LF of 6-inch force main, and a new 0.25 MGD lift station to transport the domestic wastewater to the Lewisport Collection System.

Beyond the design, Bluegrass Engineering was tasked with acquiring easements, gas line encroachment permits, DOW Floodplain Construction Permit(s), KTC Encroachment Permit, CSX Encroachment Permit, construction administration, resident inspection and County ROW Permit.

The Solution & Result

This project is another example of similar projects that our firm has recently worked on that deals with some of the challenges MUPB finds in front of them: addressing a system failure and regaining regulator-compliant operations. Aleris was in need of a long term treatment of the domestic wastewater after the failure of their existing WWTP. This improved service to the Aleris facility allowed for the allocation of company resources to be placed within the operations of the facility rather than constructing, operating and maintaining a WWTP.

Key Features
  • Delivered full engineering design for the replacement of Aleris Aluminum’s failed domestic WWTP
  • Designed and coordinated installation of 1,000 LF of 8″ gravity sewer, 16,000 LF of 6″ force main, and a 0.25 MGD lift station
  • Managed easement acquisition and all required encroachment and floodplain permits (Gas Line, KTC, CSX, DOW)
  • Provided construction administration and resident inspection services to ensure quality and compliance
Project Relevance & Impact
  • Resolved a critical system failure and restored regulator-compliant wastewater operations
  • Reduced operational burden on Aleris by eliminating the need to operate and maintain their own WWTP
  • Allowed the facility to redirect resources back to core production activities
  • Demonstrates Bluegrass Engineering’s experience with complex utility challenges similar to those faced by MUPB