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Customer: Gould Electronics, Inc.
Engineer: Advanced GeoServices Corp.
Project: Burgess Soil Removal
Cost: $85,000
Location: Freeport, IL
Contact: Stephen Kirschner, Project Manager, (610) 558-3300
The old Burgess Battery site in Freeport, Illinois was home to a number of Industrial operations throughout the 20th century. The site was home to Burgess Battery, through most of its history, and was used as a development and production facility for dry cell batteries. After Burgess left, the facility was used for warehousing chemicals. The site has since been abandoned, and all structures on the property have been demolished.
Gould Electronics has taken over responsibility for the site from Burgess and is in the process of cleaning it up, so that it can be transferred to the City of Freeport for public use. Advanced GeoServices Corp has been hired by Gould to accomplish this.
Site investigation work performed by Advanced GeoServices indicated that soils in a number of locations around the site had elevated lead concentrations. These soils had to be removed from the site before the site could be graded and capped for final closure.
Industrial Solutions was contracted to excavate the impacted soils, and coordinate transportation to an appropriate disposal facility. A number of drums spotted around the site also had to be emptied, decontaminated, and recycled. The cost of hauling and disposal was paid directly by the owner
Excavation of the impacted soils was an interesting operation, because the limits of the contamination were not clearly defined. Rather than spending additional money to clearly define the limits of contamination, the engineer worked with the EPA to develop a work plan that allowed them to assess the extent of contamination while removing it.
The work plan approved by the EPA involved excavating a given quantity of material then testing the banks of the excavation. If the lead levels in the soils were below the cleanup criteria, excavation was stopped. If a bank tested above the cleanup criteria, excavation continued. This process was repeated at each location until a clean outer limit was found in all directions.
A site-specific health and safety plan was required for the work,, and all personnel allowed on site were 40-hour HAZWOPER trained. Safety precautions included the establishment of controlled work zones, use of PPE, and real time dust monitoring during excavation to ensure that workers were not exposed and contamination was not spread through air-borne particulate.
 Customer: ACC/GCC Chemical Company
Engineer: Golder Associates
Project: Chemplex Operable Unit 2
Cost: $3,600,000
Location: Clinton, IA
Operable Unit 2 was the second phase of the remediation of the Chemplex NPL site in Clinton, IA. The Chemplex NPL site consisted of an unlined industrial landfill and an associated contaminated groundwater plume. Operable Unit 1 addressed the contaminated groundwater plume. Operable Unit 2 addressed the landfill itself. The remedial design included installation of a soil vapor extraction system throughout the landfill and construction of an impermeable cap and surface water management system.
Industrial Solutions, Inc. performed as the prime remedial contractor for Operable Unit 2. The scope of work included:
- Consolidation and regrading of landfill waste,
- Installation of 55 soil vapor extraction wells,
- Installation of over 6,500 LF of HDPE vapor collection piping,
- Installation of a condensate collection system,
- Construction of a 1,000 SF blower building including a 125 HP SVE vacuum blower, condensate collection tank, and control system.
- Construction a 7.5 acre landfill cap including an HPDE liner, soil and vegetative cover, and surface water management system, and
- Connection to and recommissioning of the OU-1 catalytic oxidizer.
- Integration of the system with the OU-1 control system.
Health and safety was of particular concern on this project. A good portion of the work was performed on top of or in the landfill wastes, and the landfill had been used to dispose of both solid and liquid wastes with no documentation of location and quantities. Extensive sampling had been done during the site investigation, which established the types and concentrations of hazardous materials in the landfill, but there was still some uncertainty about where the various materials would be encountered.
As with Operable Unit 1, the entire project had to be completed in one construction season. Despite the tight schedule, the project was completed on time, and the owner and engineer were pleased with our performance.
 Customer: Heinz, USA Muscatine Facility
Project: Bulk Storage Tank Relocation
Cost: $470,000
Location: Muscatine, Iowa
When Heinz USA broke ground for their warehouse expansion project, there was one major obstacle in their way. Four, 30,000 gallon bulk storage tanks were located within the footprint of the new warehouse. Heinz had to move the tanks to a new location at the facility and reconnect the tanks to the kitchen.
The scope of work to move the tanks included the following:
- Construction of concrete foundations and containment structures,
- Relocation of four, 30,000 gallon tanks.
- Relocation of four product pumps and reconnection of power and controls to the pumps.
- Design and installation of piping systems required to convey products from the tanks to the kitchen.
- Design and installation of heat tracing and insulation required to maintain a constant product temperature inside conveyance piping.
- Design and installation of the steam and condensate return system to heat the tanks.
To complicate the project, the materials stored in the tanks were critical ingredients in almost all the products produced at the plant. This made execution of the work on a tight schedule critical to the projects success.
Industrial Solutions was selected for the project based on a combination of price and convenience. While Industrial Solution's proposal to perform the work was competitively priced, the deciding factor in Heinz's selection was the fact that Industrial Solutions was the only contractor that could deliver the project on a turnkey basis.
When Heinz hired Industrial Solutions, they eliminated the need to tie up their own people to coordinate between design engineers and separate civil, mechanical, and electrical contractors. They also eliminated any questions regarding who was responsible for any delays or quality issues. With Industrial Solutions responsible for design and construction of the entire project, Heinz only had to coordinate Industrial Solution's schedule with the plant's production schedule.
 Customer: University of Wisconsin-Platteville
Project: Wisconsin Energy Initiative III
Cost: $1.7M
Location: Platteville, WI
As part of the third phase of the State of Wisconsin's Energy Initiative, Industrial Solutions participated with Honeywell Home & Building Control in evaluating energy efficiency retrofits at the University of Wisconsin at Platteville.
Industrial Solutions surveyed and recommended energy improvements in all 1.5 million square feet of university space. Since this was the third energy initiative, all of the easy energy retrofits were previously completed, this phase required detailed data gathering and analysis to meet the state's requirement for a 10 year payback.
Retrofits identified by Industrial Solutions and implemented by the university include:
- Conversion of multiple systems from constant volume to variable air volume.
- Implementation of additional and expanded energy management system capabilities.
- Water & sewer reductions through fixture retrofits.
- Sewer credits for cooling tower water use.
Since this is a guaranteed savings performance contract, the enhanced energy management system will be used to verify the performance of the implemented retrofits. If savings are not achieved, the university will be reimbursed the difference.
 Customer: Whiteside County Highway Department
Engineer: Rust Environment & Infrastructure, Inc.
Project: Leachate Storage & Force Main Construction
Cost: $395,000
Location: Morrison, IL
Contact: (815)772-7651
The Whiteside County Highway Department inherited responsibility for the closed Whiteside County Landfill in Morrison, Illinois. The landfill was an unlined municipal landfill that, at times, took industrial waste as well as domestic garbage. It was determined that leachate is migrating out of the landfill and impacting the water quality of the local aquifer.
Rust Environment & Infrastructure designed a leachate collection system to intercept the leachate as it percolates out of the landfill. The system consists of 4 horizontal wells drilled under the landfill, a force main, and storage. Industrial Solutions was awarded the contract to build the force main and storage. The horizontal wells were drilled under a separate contract.
The storage tank is a 50,000 gallon bolted steel tank with a concrete secondary containment structure. The force main is dual containment HDPE line with leak detection. Industrial Solution's contract also included installation of a leachate load-out pump, insulation of the tank and above ground piping, and all instrumentation and controls.
Customer: ACC/GCC Chemical Company
Engineer: Montgomery Watson
Project: Chemplex Operable Unit 1
Cost: $6,400,000
Location: Clinton, IA
Contact: Tom Belick, Erler & Kalinowski, Inc., (650) 655-4955
Chemplex Operable Unit 1 was the first project performed by the Helm Group in the environmental remediation field.
The Chemplex NPL site, located in Clinton, Iowa consisted of an inactive industrial landfill and an associated plume of contaminated groundwater. The landfill was an unlined disposal site for both solid and liquid wastes generated by a plastic manufacturing facility in the 60's and 70's. Groundwater contamination associated with the site covered approximately 350 acres, and had spread to 3 separate aquifers. The primary contaminants of concern were chlorinated hydrocarbons and other volatile organic compounds.
Civil Constructors was contracted as the prime remedial contractor to construct a groundwater extraction and treatment system designed to contain the contaminated groundwater plume. The scope of work included construction of a 14,500 square-foot treatment facility and five lift stations, installation of extraction pumps, and placement of over 65,000 linear feet of sub-grade, fiberglass conveyance piping. The system's 51 extraction wells were installed under a separate contract.
The treatment facility was designed to handle 2 waste streams at 250 gpm each. Treatment technology incorporated in the system included pH adjustment, green-sand filtration, air stripping with catalytic oxidation, and liquid phase carbon adsorption. The entire system including the lift stations and wells was PLC controlled with a graphical PC interface.
Because of regulatory deadlines, the project had to be performed on a very fast track schedule with the entire project completed in 6 months. Civil met the project's tight schedule, and the requirements of the owner and engineer. Fred Hinker of Montgomery Watson noted in a memo summarizing his review of the project at startup:
"At the time of my visit it was obvious that Montgomery Watson's representatives and the contractor were working very well together as a team. If progress continues as well as it looks like things have gone so far, then I believe this will be a very successful project in the eyes of Montgomery Watson, the client, and the contractor. Start up is proceeding smoothly and the subcontractors are working well together toward completion."
Industrial Solutions, Inc. was incorporated shortly after the completion of Chemplex OU-1 to dedicate resources to the pursuit of environmental projects.
 Customer: Freeport Memorial Hospital
Project: Energy and Infrastructure Revitilization
Cost: $5.5M
Location: Freeport, IL
It had been years since Freeport Memorial Hospital had funds available to upgrade their aging infrastructure. Their single stage absorption chillers had been patched as many times as possible, their boilers were in need of replacement, the internal parts of their aging deaerator were long gone, and many of their air handling units were in need of major repair. They had completed an energy performance contract approximately 7 years prior so the quick payback items such as lighting had already been performed. As part of a second Energy and Infrastructure Revitalization project, Industrial Solutions participated with Honeywell Home & Building Control in evaluating additional energy and operational improvement opportunities to help in upgrading their aging infrastructure.
Industrial Solutions surveyed, recommended, justified, and designed the following facility upgrades:
- Conversion of multiple systems from constant volume to variable air volume with VAV box installation.
- Replacement of the existing single stage absorption chillers with new high efficiency electric centrifugal chillers.
- New boiler and deaerator plant.
- Conversion of an electric boiler facility to natural gas.
- Installation of a 350 KW natural gas engine generator set.
- Complete energy management system and direct digital control upgrade.
The systems were also designed and installed in phases to allow for the critical cooling system to be installed and on-line before the start of the cooling season, even though project approval was not received until the end of January. The remaining systems were phased in through the remainder of the summer and into the fall.
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