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Water

Chetolah Creek Water Reclamation and Reuse Facility Improvements

Hays, Kansas

Innovative design-build team delivers significant savings

Market

Water

Key Services

Construction

Preconstruction

Self-Perform

Strategic Partnerships

Delivery Method
Design-Build (DB)
Capacity
7.5 MGD

The challenge

The City of Hays, Kansas, needed to renovate its Chetolah Creek Water Reclamation and Reuse Facility to replace aging infrastructure and meet stricter discharge limits. The facility was built in 1953, and approximately one-third of its installations had exceeded their service lives. CAS Constructors, an Alberici enterprise, was engaged to make improvements to the biosolids treatment process, complete electrical upgrades, and expand the city’s reuse storage capacity.

Key Facts

$2 million saved


1 million+ safe work hours


Completed 59 days ahead of schedule


21% reduction in power consumption

Challenge met

A CAS Constructors joint venture generated multiple value engineering ideas to help the city meet its budget for Chetolah Creek Water Reclamation and Reuse Facility, ultimately saving the city $4 million. Construction of the new plant was completed adjacent to the existing facility, which was kept in operation throughout construction. To transition to the new systems, the team completed extensive tie-in work, including multiple overnight tie-ins when flow was lower. Completing the final tie-in required bypassing the city’s flow for a week, so CAS Constructors developed detailed plans with the city and its engineer to ensure all stakeholders agreed with and understood the approach. Despite Hays receiving near-record rainfall, substantial completion was achieved nearly two months ahead of schedule. The collaborative strength of the design-build delivery format allowed the entire team, including the City of Hays, the City’s engineer, and the design-build joint venture, to identify and resolve issues efficiently.

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