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Acceptance of Kerper Boulevard Sanitary Sewer Project Copyrig hted December 7, 2020 City of Dubuque Consent Items # 6. City Council Meeting ITEM TITLE: Acceptance of Kerper Boulevard Sanitary Sewer Project SUM MARY: City Manager recommending acceptance of the public improvement contract for the Kerper Boulevard Sanitary Sewer Reconstruction Project, as completed by Tschiggfrie Excavating Co. RESOLUTION Accepting the Kerper Boulevard Sanitary Sewer Reconstruction Project and authorizing the payment to the contractor SUGGESTED Suggested Disposition: Receive and File;Adopt Resolution(s) DISPOSITION: ATTACHMENTS: Description Type Kerper Boulevard Sanitary Sewer Project-MVM Memo City Manager Memo Staff Memo Staff Memo Resolution Resolutions Award Memo Supporting Documentation Dubuque THE CITY OF � ui-Aseria cih DuB E , . � . , � II � Maste iece on tj2e Mississi i zoo�•zoiz•zois YP pp zoi�*zoi9 TO: The Honorable Mayor and City Council Members FROM: Michael C. Van Milligen, City Manager SUBJECT: Kerper Boulevard Sanitary Sewer Reconstruction CIP 7102663 DATE: December 1, 2020 City Engineer Gus Psihoyos is recommending acceptance of the public improvement contract for the Kerper Boulevard Sanitary Sewer Reconstruction Project, as completed by Tschiggfrie Excavating Co., in the final contract amount of$2,423,630.89, which is a 6.33% increase from the original contract amount of$2,279,444.90. The increase in costs was due to contract items that ran over such as pavement, curb and gutter, and backfill material due to unforeseen subsurFace conditions. Change orders in the amount of $66,861.07 made up the rest of the overage and were due to unforeseen rubble disposal, slope stabilization around the box culvert, and an added redundancy for emergency by-passing of the new lift station. I concur with the recommendation and respectfully request Mayor and City Council approval. Y Mic ael C. Van Milligen MCVM:jh Attachment cc: Crenna Brumwell, City Attorney Cori Burbach, Assistant City Manager Gus Psihoyos, City Engineer Dubuque THE CITY OF � All•pmerisa Ci$ Du8 E �m��,��, h� , � �.� , I I MRste iece on the MisSiSsi i zoo�•zoiz=zois � pp zoi�*zot9 TO: Michael C. Van Milligen, City Manager FROM: Gus Psihoyos, City Engineer DATE: November 30, 2020 SUBJECT: Kerper Boulevard Sanitary Sewer Reconstruction CIP 7102663 INTRODUCTION The enclosed resolution provides for the acceptance of the Public Improvement Contract for the Kerper Boulevard Sanitary Sewer Reconstruction Project. BACKGROUND The City experienced a significant sanitary sewer overflow in August 2015 in a heavy industrial area along Kerper Boulevard. The overflow prompted an extensive investigation as to how and why the overflow occurred. The investigation by City staff found the overFlow had occurred due to premature weakening of the sanitary sewer. The failed section of sanitary sewer was located through a 66-inch diameter storm sewer which allowed wastewater to enter the storm sewer. An emergency repair was conducted, along with heavy cleaning of the sanitary sewer. During heavy cleaning operation of the Kerper Boulevard and the East 16t" Street sanitary sewers, significant offset pipe joints and additional corroded pipe section were discovered. During the pipe cleaning operations, the cleaning equipment was lodged in the ductile iron sanitary sewer pipe. A second emergency excavation was conducted to retrieve the cleaning equipment. Due to the condition of the existing ductile iron pipe only a temporary repair could be made. A permanent repair was not feasible as pipe corrosion presented difficulties in securing the sewer repair couplings. Since there are so many locations where corrosion had affected the pipe along this section of Kerper Boulevard, it was recommended that full replacement and relocation of the sanitary sewer be made. DISCUSSION The Kerper Boulevard Sanitary Sewer Reconstruction Project included the full replacement of the failed gravity sewer system, on Kerper Boulevard, with a combination of a force main and gravity system. The new alignment connected to a 24- inch diameter sanitary sewer with sufficient capacity to accept flows from the Kerper Boulevard industrial area and utilized a single lift station and force main. The new alignment is located along the U.S. Highway 151/61 corridor, between E. 16t" Street and Kerper Boulevard. The new alignment eliminated the Kerper Boulevard sanitary flow from entering the existing undersized sanitary sewer at E. 16t" Street and Kerper Boulevard. The Kerper Boulevard Sanitary Sewer Reconstruction project was completed by Tschiggfrie Excavating Co. of Dubuque, lowa in the final contract amount of $2,423,630.89, which is a 6.33% increase from the original contract amount of $2,279,444.90. The increase in costs was due to contract items that ran over such as: pavement, curb and gutter, and backfill material due to unforeseen subsurface conditions. Change orders in the amount of $66,861.07 made up the rest of the overage and were due to unforeseen rubble disposal, slope stabilization around the box culvert, and an added redundancy for emergency by-passing of the new lift station. Attached is the award memo explaining the history of the project along with the details for the complete redesign after the initial bids for the project were rejected. RECOMMENDATION I recommend that the City Council accept the improvements and authorize the payment of the contract amount of $2,423,630.89 to Tschiggfrie Excavating Co. for the Kerper Boulevard Sanitary Sewer Reconstruction Project. BUDGETIMPACT The project cost for the Kerper Boulevard Sanitary Sewer Reconstruction Project is summarized as follows: Description Estimate Award Final Construction $ 3,894,152.10 $ 2,279,444.90 $2,423,630.89 Emergency Costs, Maintenance 469,822.00 469,822.00 489,822.00 Costs b - ass Pum in Contingency 389,415.21 389,415.21 0.00 Contract Admin / Construction 214,178.00 214,178.00 500,154.05 En ineerin 4.967.567.31 3.352.860.11 3.413.606.94 The project funding is as follows: CIP Fundinq Source Amount 7102663 Kerper Blvd Sanitary Sewer Reconstruction $2,423,630.89 State of lowa, Revolvin Loan Fund Emergency Costs, Maintenance Costs (by-pass 489,822.00 Pum in 7102663 Kerper Blvd Sanitary Sewer $ 500,154.05 Construction, Desi n, Administration & Ins ection Total Project Funding $3�413,606.94 ACTION TO BE TAKEN I respectfully request adoption of the attached resolution accepting the improvements and authorizing payment of the contract amount of $2,423,630.89 to Tschiggfrie Excavating Co. for the Kerper Boulevard. Sanitary Sewer Reconstruction Project. cc: Jenny Larson, Budget Director John Klostermann, PW Director Prepared by Adrienne N., Breitfelder, City Clerk Address: City Hall- 50 W. 13th St Telephone: (563) 589-4100 Return to: Adrienne N., Breitfelder, City Clerk Address: City Hall- 50 W. 13th St Telephone: (563) 589-4100 RESOLUTION NO. 348-20 ACCEPTING THE KERPER BOULEVARD SANITARY SEWER RECONSTRUCTION PROJECT AND AUTHORIZING THE PAYMENT TO THE CONTRACTOR WHEREAS, the public improvement contract for the Kerper Blvd. Sanitary Sewer Reconstruction Project, (the Project) has been completed by the Contractor, Tschiggfrie Excavating, Co. (Contractor), the City Engineer has examined the work and recommends that the Project be accepted; and WHEREAS, the final contract amount for the Project is $2,423,630.89; WHEREAS, the Contractor has previously been paid $2,392,449.35, leaving a balance of $31,181.54; and WHEREAS, the City Council finds that the recommendation of the City Engineer should be accepted. NOW, THEREFORE, BE IT RESOLVED BY THE CITY COUNCIL OF THE CITY OF DUBUQUE, IOWA: Section 1. The recommendation of the City Engineer is approved, and the Project is hereby accepted. Section 2. The Finance Director is hereby directed to pay to the Contractor the balance of the retainage of $31,181.54 as provided in Iowa Code chapter 573, and to pay such retainage in accordance with the provisions of Iowa Code chapter 573 or Iowa Code chapter 26.13. Passed, approved, and adopted this 7th day of December 2020. Roy D uol, Mayor Attest: n"'71t A. Adrienne N. Breitfelder, eity Clerk CITY ENGINEER'S CERTIFICATE OF FINAL COMPLETION OF KERPER BLVD. SANITARY SEWER RECONSTRUCTION PROJECT The undersigned City Engineer of the City of Dubuque, lowa, hereby certifies that he has inspected the Kerper Blvd. Sanitary Sewer Reconstruction Project has been perFormed in compliance with the terms of the Public Improvement Contract, and that the total cost of the completed work is $3,413,606.94. Dated this 1St day of December 2020. Gus Psihoyos, City Engineer Filed in the office of the City Clerk on the 1 St day of December 2020. �� r , }.-7 i-' _ f r'� ..,i,x'i.� � ! . i •'e � . . . ,. � , r� . . .. � ' � Adrienne N. Breitfelder, City Clerk Dubuque THE CITY QF � All•�nenc�Clry DU B E .��.����_��� '� II��' Masterpiece on the Mississippi Z°°'-Z°lZ 2013-2017 TO: Michael C. Van Milligen, City Manager FROM: Gus Psihoyos, City Engineer DATE: November 8, 2018 SUBJECT: Kerper Blvd. Sanitary Sewer Reconstruction CIP 7102663 INTRODUCTION The enclosed resolution authorizes the award of the construction contract for the Kerper Blvd. Sanitary Sewer Reconstruction. BACKGROUND The City experienced a significant sanitary sewer overflow in August 2015 in a heavy industrial area along Kerper Boulevard. The overflow prompted an extensive investigation as to how and why the overFlow occurred. The investigation by City staff found the overFlow had occurred due to premature weakening of the sanitary sewer. The failed section of sanitary sewer was located through a 66-inch diameter storm sewer which allowed wastewater to enter the storm sewer. An emergency repair was conducted; along with heavy cleaning of the sanitary sewer. During heavy cleaning operation of the Kerper Boulevard and the East 16th Street sanitary sewers, significant offset pipe joints and additional corroded pipe section were discovered. During the pipe cleaning operations, the cleaning equipment was lodged in the ductile iron pipe. A second emergency excavation was conducted to retrieve the equipment. Due to the condition of the existing ductile iron pipe only a temporary repair could be made. A permanent repair was not feasible as pipe corrosion presented difficulties in securing the repair couplings. Since there are so many locations where corrosion has affected the pipe, along this section of Kerper Blvd., it is being recommended that full replacement and relocation of the sanitary sewer be made. While sections of the collection system along Kerper Boulevard are in fair to good condition, approximately 2,400 feet of 18-inch diameter ductile iron sanitary sewer is at risk between Fengler Street and East 16t" Street. Additionally, approximately 1,800 feet of 18-inch diameter vitrified clay sanitary sewer along East 16th Street is distressed and in need of replacement to eliminate I&I issues due to settlements. Additionally, the 18-inch vitrified clay pipe is under sized to serve the current level of development. The 18-inch ductile iron pipe, along Kerper Boulevard, was installed in 1994 and the 18-inch vitrified clay pipe, along East 16t" Street, was installed in 1957. The reason for the premature failure of the ductile iron pipe is unclear, however, following several attempts to clean, televise, and repair the sewer it was discovered that the pipe wall thickness is severely compromised. Further, the existing manholes show signs of sulfuric acid attack and the section of pipe removed during the repair made in August of 2015 showed signs of extensive corrosion. Many reasons are known as to how hydrogen sulfide can develop in a system such as low pH in the wastewater and reduced velocity or increased retention time of wastewater in the collection system. Engineering staff have identified several different issues with the Kerper Blvd. sanitary sewer and investigated different options for the replacement of the sewer. Staff selected one of the options and issued the design for bidding in May of 2017. The estimated construction cost of the project was $3,762,675.00. Two Bids were received on June 8, 2017, for the Kerper Blvd, Sanitary Sewer Reconstruction project. The bids were substantially over the estimated construction cost with a low bid of$5,494,539.26, both bids were rejected. DISCUSSION Engineering staff re-evaluated the design for cost saving measures and developed three additional design alternatives for consideration. The selected alternative is for full replacement of the failed gravity sewer system, on Kerper Boulevard, with a combination of a force main and gravity system. The new alignment will start at an existing manhole, connected to a 24-inch diameter sanitary sewer with sufficient capacity to accept flows from the Kerper Boulevard service area. Approximately 2/3 of the project will be able to be constructed within public right-of-way, the remaining 1/3 will be constructed on easements across private property. The selected alternative reduces estimated construction costs and impact to businesses and traffic along E. 16th Street, near Kerper Blvd. This was achieved by modifying the previous alignment and utilizing a single lift station and force main. The modified alignment is located along the U.S. Highway 151/61 corridor, between E. 16t" Street and Kerper Blvd. The single lift station allows for a much shallower pipe installation and avoids the need for dewatering and specialized trench shoring for that portion of the project. This alignment modification also eliminated the majority of pavement replacement costs on E. 16th Street and at the intersection with Kerper Blvd. This change in alignment also avoids the need to close the U.S. Highway 151/61 ramps, at Kerper Blvd., and virtually eliminates the access impact to businesses along E. 16t" Street. Additionally, the new project scope eliminates the costs associated with the replacement of the 1950's era sanitary sewer along East 16t" Street. Currently the existing sewer is undersized for the area that it serves. The modified alignment eliminates the Kerper Blvd. sanitary sewer flow from entering the existing undersized sanitary sewer on E. 16t" Street. The elimination of the Kerper sanitary sewer flow, from the E. 16t" Street sanitary sewer, also has the potential to reduce future sewer replacement costs. The existing sewer, on E. 16t" Street, could be replaced with a smaller diameter pipe and at a reduced depth. 2 In late July, Engineering staff revised the previously submitted and approved facility plan to reflect the revised concept. The estimated cost of$3,774,954.70, for the revised concept, was also included as part of the amended facility plan. The lowa Department of Natural Resources (IDNR) have reviewed and approved the amended facility plan so that the City can apply for a SRF loan to cover construction and contingency cost. The Engineering and design costs will be paid by the sanitary construction fund. The final design was completed the week of October 1St, along with a construction cost estimate based on the completed design. The final construction cost estimate including, a contingency of$389,415.00 is $4,283,567.31, which is $508,612.61 more than what was submitted with the facility plan, in July, and $1,083,567.00 more than the previously approved Intended Use Plan (IUP). The plans, specifications, estimate and IUP application were approved by the IDNR, and a sanitary sewer construction permit has been issued to the City of Dubuque for the project. While there have been costs related to the delay in completing the project by not awarding the $5,494,539 bid in June 2017 the savings have far outweighed those additional costs. In April 2017, the Public Works department began continuous pumping which included staff supervision of those pumps in order to get all the businesses along Kerper Blvd operating. The cost to the City during this period including equipment, fuel, piping and labor is estimated at $762,000. The savings on the redesign and rebid construction project is $3,215,000. This savings to the City of Dubuque by redesigning the project after having rejecting the original bid is $2,453,000 minus design work which was done by the City of Dubuque Engineering Department staff. BID RESULTS Sealed bids were received on the project on November 8, 2018. Tschiggfrie Excavating Co. of Dubuque, IA submitted the low bid in the amount of $2,279,444.90. This amount is 42.11% under the estimate of probable cost. A summary of the bid proposals is as follows: Contractor Name Total Bid Tschiggfrie Excavating Co. $2,279,444.90 Langman Construction $2,847,702.66 Legacy Corporation of IL $2,860,880.00 Boomerang Corp. $3,007,428.70 Topgrade Excavating, Inc. $3,203.113.10 Portzen Construction $3,281,321.67 Miller Trucking & Excavating $3,690,964.66 WC Stewart Construction $3,883,299.72 3 RECOMMENDATION I recommend that the contract for Kerper Blvd. Sanitary Sewer Reconstruction Project.be awarded to Tschiggfrie Excavating Co. of Dubuque, lowa in the amount of$2,279,444.90. Pending Approval from the lowa Financing Authority (IAF). lowa Department of Natural Resources (IDNR) has stated all items are eligible. BUDGETIMPACT The summary of cost for the Kerper Blvd. Sanitary Sewer Reconstruction Project is summarized as follows: Description Estimate Award Construction $ 3,894,152.10 $ 2,279,444.90 Emergency Costs, Planning & Design 469,822.00 469,822.00 Contingency 389,415.21 389,415.21 Contract Admin / Construction Engineering 214,178.00 214,178.00 $ 4,967,567.31 $ 3,352,860.11 The project funding summary is as follows: CIP Fundin Source Amount 7102663 Kerper Blvd Sanitary Sewer Reconstruction $ 4,308,300.00 State of lowa, Revolvin Loan Fund 7102663 Kerper Blvd Sanitary Sewer $ 684,000.00 Construction, Desi n, Administration & Inspection Total Project Funding $ 4,992,300.00 ACTION TO BE TAKEN The City Council is requested to award the contract for the Kerper Blvd. Sanitary Sewer Reconstruction Project to Tschiggfrie Excavating Co. through the adoption of the enclosed resolutions. Prepared by Todd Irwin, Engineering Technician cc: Jenny Larson, Budget Director John Klostermann, PW Director Deron Muehring, Civil Engineer 4