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 Project Spotlight


 

 

 

 

 

 

Mosaic - Green Bay Regional Holding Pond Phase I

Owner: Mosaic

Location: Mosaic Green Bay Plant

 

Project Scope:

  • Installed 9,500,000 sq. ft of 80 mil textured and smooth liner
  • Dug out 142 ballast trenches along the slopes, in total length of 15,600 feet.
  • Installed 1000 bags of rip-rap at the pond corners.

Project Description:

RHP is a project that arose after Mosaic Fertilizer Company encountered serious water storage problems due to the recent hurricane activities in Florida. The existing ponds were filled near capacity and the management at Mosaic decided to build a new one to alleviate the problem. The challenge was in the timing. The pond was supposed to be done in the middle of the rainy season in Florida. The project’s dirt work started mid April and the prolonged rain period pushed the completion well into July. That pressed COMANCO into the accelerated schedule with the due date on finishing the liner work at the end of August. Basically, we were given six weeks to complete liner installation of the first phase.

The only way to achieve the project goal was to establish work in two shifts. The main job for the day shift was to install ballast trenches and deploy as much liner as possible. The crew that worked at night took care of detailing and pumping any excess water off the liner.

Heavy rains during construction saturated the sub grade so the only way to install the liner was to use an excavator for deployment. Extra technicians were used to clean and prepare each seam for welding. Heat during the day reached a scalding 107 degrees and it was a challenge to keep the crew hydrated. Excavating the ballast trenches and their compaction after liner installation was another problem. The slopes were so wet that the dozer started squeezing the soil out of the trenches. It took extra effort to pack the soil back into the trenches.

 

 

After six weeks of intense work, Phase I was completed on August 23rd. Mosaic’s three plants started pumping processed water into the pond immediately after completion.

The management at Mosaic was so pleased with COMANCO’s dedication and determination to complete the pond on time, that they organized a Bar-b-queue for the contractors involved and even printed shirts for the crew.

The significance of the project lies in fact that we delivered our best when the customer needed us the most. If we didn’t finish the project on time they probably would have encountered a process water release, faced environmental problems, and stiff fines.

* If you would like to know more about the Mosaic Regional Holding Pond Project or any other project delivered by The COMANCO Group, please contact Mr. Larry Holmes at (813)988-8829