District Engineer and Project Manager – Castro Valley Sanitary District
General Overview
As District Engineer, Dr. Lewandowski managed the design and performed quality assurance reviews on three major trunk sewer replacement projects with total length of about 3.5 miles, with sewer diameters from 10-inch to 27-inch diameter. He also managed construction of two major trunk sewer replacements with total length of over two miles and sewer diameters from 12-inch to 27-inch diameter and capital costs of $6 million. Both sewer projects were developed to meet SRF funding requirements.
He managed design and construction of three smaller sewer replacement (pipebursting and open cut) and repair projects with total construction costs of about $1.5 million.
Dr. Lewandowski developed a Master Plan update to determine how proposed trunk sewers replacement and repairs could be modified to reduce costs. He confirmed that proposed revisions in District trunk sewer replacements would provide adequate capacity to reduce and/or eliminate overflows. The Master Plan update outlined guidance for repairs of defective sewers and approaches for elimination of inflow and infiltration (I/I). He also developed a collection system model update, and used new flow metering results to reassess R values and to confirm design peak wet weather flows.
Dr. Lewandowski also managed or coordinated numerous other projects and tasks, including environmental reviews for proposed projects, including coordination with State SRF funding managers to provide necessary documentation to obtain the PFC and FPA and ongoing reporting for requests for reimbursement. He was involved with District standards revision and development and performed plan and permit reviews for large projects. He assisted with review of potential improvements for managing sewer damage risk from seismic and other geologic hazards.
Master Planning
CVSan Master Plan Update – Dr. Lewandowski managed and developed the District’s 2012 Master Plan Update. The update was necessary for reassessment of 2006 Master Plan costs, as well as for reviewing alternative options to reduce costs for master plan improvements. The update included flow monitoring and I/I assessment for the collection system model. Further I/I analysis was performed using both smoke testing and a preliminary I/I investigation of defects located near storm drain crossings. Modeling updates of the collection system confirmed that proposed revisions would enable reduced costs for trunk sewers. A thorough review of previous District planning, design and construction costs was completed to develop new unit costs for proposed alternative trunk sewer replacement options. Alternative approaches with varying levels of cost were developed based on risk of surcharge and overflow under 5-year and 10-year rainfall events.
CVSan Collection System Model Update – Dr. Lewandowski directed District staff flow metering efforts to provide flow information for collection system modeling and to identify sources of high inflow and infiltration (I/I) within the District. He developed and assessed R values (percent of rainfall entering the system) from storm events and calibrated the model timing of the I/I to correspond with flow measurements at flow meter sites.
Sewer Design and Construction
MPP1 Phase 1 – Critical Repairs
This sewer repair project included removal and replacement of 12 sewer segments between existing manholes, with spot repairs on 2 additional segments. Sewer sizes ranged from 6-inch to 8-inch diameter. Some sewer segments were upgraded during design to meet current District design standards. Dr. Lewandowski managed design work, provided design review of consultant deliverables for compliance to District standards and completed environmental documentation. During construction, he also assisted District inspection staff with RFIs, design questions during construction, change orders and claim review. Construction cost was $750K
Design and Construction completed in 2008.
MPP1 Phase 2 – Critical Repairs
This sewer repair project included removal and replacement or new installation of over 1,700 feet of sewer in five different locations in the District. Replacement sewer sizes ranged from 8-inch to 10-inch diameter. Some sewer lines were upgraded during design to meet current District design standards. Dr. Lewandowski managed design work up to 90 percent design, and assisted District staff with review of consultant deliverables for compliance to District standards for final design. He also assisted District inspection staff with RFIs and design questions during construction. Construction cost was $800K.
Construction completed in 2013.
MPP2 –Phase 1 Sewer Replacements – Lake Chabot Road Trunk Sewer
This sewer replacement project provided peak wet weather flow capacity for historically surcharging areas and hydraulic capacity for 10-year peak wet weather events. The MPP2-P1 Sewer Project (Lake Chabot Road Trunk Sewer) initially included design and construction of approximately 6,000 feet of 10-inch to 15-inch diameter trunk sewer replacement. However, using updated modeling of the sewers performed by Dr. Lewandowski, the project length and cost were reduced during design by about 30 percent from the 2006 Master Plan. The rerouting of sewers allowed the overall sewer construction and replacement length to be reduced to about 4,300 feet, with a maximum diameter of 12-inch. Some of the proposed revised sewers allowed parallel construction, which reduced both the amount of roadway surfaces impacted within the area and the traffic inconvenience. Dr. Lewandowski managed design work, provided design review of consultant deliverables for compliance to District standards and completed environmental documentation. During construction, he also assisted the CM consultant with RFIs, design questions during construction, change orders and claim review. Construction cost was $1.5 million.
Castro Valley Boulevard Streetscape Trunk Sewer
This sewer replacement project provided peak wet weather flow capacity for historically surcharging areas and hydraulic capacity for 10-year peak wet weather events. The Castro Valley Boulevard Streetscape Trunk Sewer Project included design and construction of approximately 6,700 feet of primarily 18-inch and 24-inch diameter sewers. This project combined two 2006 Master Plan projects for a significant cost savings. The new trunk sewer was installed parallel to the existing sanitary sewer along Redwood Road and replaced sewers along Castro Valley Boulevard. The existing parallel 6-inch and 8-inch sanitary sewers along Castro Valley Boulevard were undersized and subject to blockage from high FOG loading. The smaller parallel sewers along busy Castro Valley Boulevard which had previously required extensive and frequent maintenance were abandoned as part of the project, saving on maintenance costs. Parallel sewers along Redwood Road were diverted to the new trunk to minimize peak flows and surcharging in these small diameter sewers. The diversions on Redwood Road allowed existing sewers to carry peak wet weather flows, and a full line replacement was no longer necessary. The project was a joint project with the County Redevelopment Agency which combined the trunk sewer project with the Castro Valley Boulevard Streetscape project. Dr. Lewandowski managed design work, provided design review of consultant deliverables for compliance to District standards and completed environmental documentation. During construction, he also assisted the CM consultant and District staff with RFIs, design questions during construction, change orders and claim review. Construction cost was $3.5 million.
MPP4-P1 – Forest Avenue/Sandy Road Trunk Sewer
The MPP4-P1 (Forest Avenue/Sandy Road Trunk Sewer) Sewer Project included replacement of approximately 7,200 feet of existing sewer with 10-inch through 18-inch diameter sewers. The sewer replacement included an overcrossing of an existing stream channel, as well as an assessment of pipe bursting options. Dr. Lewandowski modeled two alternate routes to determine whether a shorter, lower cost route would be viable. Dr. Lewandowski managed design work, provided design review of consultant deliverables for compliance to District standards and assisted in review of environmental documentation. The Engineer’s estimate of probable construction costs was $2.7 million.
MPP3-P1 – Sewer Spot Repairs
The MPP3-P1 Sewer Improvements include repair of sewer defects identified from video inspection logs. Dr. Lewandowski developed a project design approach which included project binders to allow review of record drawings, utility information and video inspection data for confirmation of sewer repair needs. The project included from one to three spot repairs on thirteen sewer segments located throughout the District. Dr. Lewandowski coordinated staff design work and provided design review of staff deliverables for compliance to District standards. During construction, he also assisted District inspection staff with RFIs and design questions during construction. The Engineer’s estimate of probable costs was $155K.
Short Sewer Replacements and Repair Projects
Dr. Lewandowski coordinated and managed design and performed design reviews of deliverables for compliance to District standards for a number of short length sewer replacements and repair projects. These projects were designed by consultants or by District staff. He also assisted with construction phase design services and construction revisions, including review of RFIs and assistance with change order issues.
I-580 Grove Sewer – This sewer replacement project designed by a consultant included relocation of an existing 10-inch diameter sewer to accommodate the construction of a new I-580 off ramp onto Grove Way. Dr. Lewandowski coordinated with the Alameda County Transportation Commission and the consultant regarding review and modifications of plans and specifications to meet District design standards.
Heyer Avenue Sewer Replacement - This sewer replacement project designed by a consultant included removal of two 6-inch diameter sewer lines and replacement with 8-inch diameter sewers for a length of 440 feet. This $60K project was completed in 2009.
San Miguel Sewer Replacement - This sewer replacement project designed by a consultant included pipebursting of approximately 800 feet length of 6-inch diameter sewer lines with 8-inch diameter HDPE pipe. This $100K project was completed in 2010.
Craig Court Emergency Sewer Repair - This sewer replacement project designed by District staff included pipebursting of approximately 300 feet length of 6-inch diameter sewer lines with 8-inch diameter HDPE pipe. Construction work was in backyard easement areas. This $40K project was completed in 2011.
Pump Stations
Pump Station 3 Storage and Site Improvements –The Pump Station 3 site has very limited wetwell storage available in case of pumping failures or power outages. It is also located very close to Lake Chabot. Dr. Lewandowski performed preliminary storage tank design, including tank hydraulic analysis and sizing for automatic gravity filling during peak wet weather or pump outages and draining by gravity during low flows. He identified yard improvements to facilitate vehicle access in emergencies, as well as safety and seismic reliability improvements.
(May 2007-Oct 2007)
Pump Station 5 Bypass Valve Box, Site Improvements and Control System Upgrade –After a series of pumping system failures, first to the check valve in the wetwell and then from leakage due to joint failure in the discharge piping, Dr. Lewandowski managed design and construction of a pump station modification to relocate the check valves to a surface access vault. The design separately included the initial District installation of a bypass pumping vault that could be accessed with temporary pumping if the pump station operation failed. Dr. Lewandowski designed the new layout for the pump station valves and bypass. He assisted District staff with bidding and award. During construction, he also assisted the District inspector with responses to RFIs, design questions during construction and change orders. Following completion of the pumping system improvements, a pump station controls revision was performed to meet electrical code requirements. Dr. Lewandowski coordinated with a consultant for design of the relocation of power and control system from a below ground drywell to an above ground control panel.
Pump Station 5 Controls Revision Design and Construction (Jan 2012- Aug 2012): Coordinated design with consultant for relocation of power and control system from a below ground drywell to an above ground control panel. District staff performed bidding and construction management.
Other Studies and Projects
Collection System Master Plan Environmental Review for SRF Funding – (Sep 2008-Jun 2009) Dr. Lewandowski coordinated with the environmental review consultant to develop an Initial Study and Mitigated Negative Declaration (IS/MND) for the entire 2006 Master Plan set of projects. He assisted with site visits and mapping of sewer project sites, and reviewed both biological assessments and archaeological assessments. He reviewed the IS/MND and coordinated with the consultant to include all CEQA-plus requirements for SRF funding. Later, when individual projects were designed, he developed the IS/MND for two individual trunk sewer projects (MPP2 and Streetscape projects) and provided coordination and review of Section 106 studies for archeological studies necessary for SRF funding on the two projects. He coordinated the inclusion of Mitigation Monitoring and Reporting Plan (MMRP) requirements into project specifications.
SRF Funding Coordination – Dr. Lewandowski coordinated with State SRF funding managers to provide necessary documentation for PFC and FPA for SRF funding of the master plan sewer projects. He assisted District staff with gathering all necessary information for State required submittals and coordinated with District counsel to obtain other necessary documentation. He developed summary spreadsheets and quarterly reports for trunk sewer SRF funded projects for submittal for soft cost and construction cost reimbursement.
Standards Development - To create a more efficient and standardized design approach, Dr. Lewandowski developed revised standard design criteria, standard drawings, and specifications for sewer construction. New standards were developed where additions were necessary. A new set of technical specifications was developed to be used as a basis for construction of all master plan sewer projects. He also provided updates to the District Sewer Code to make it both internally consistent and consistent with the latest California Plumbing Code.
Plan and Permit Review – Dr. Lewandowski performed plan and permit reviews on large projects proposed within the District, such as the new Sutter Hospital, and on other projects which included a large number of new connections. He also provided as-needed QA/QC reviews on standard plan submittals reviewed by District staff as well as assistance on review of non-standard submittals.
Aerial/Fault Sewer Crossing Projects Review - (May 2007 – October 2007) A facilities study was developed to identify potential damages and risks from seismic events or other geologic hazards at aerial sewer crossings and where the trunk sewer crosses the Hayward Fault. Dr. Lewandowski coordinated and assisted with inspection of sites with the Consultant and reviewed proposed improvements for risk reduction at each site.
Chemical Root Control – Dr. Lewandowski coordinated the preventive maintenance chemical root control program, including development of an RFP for the contractor selection and review and selection of sewer segments scheduled for root treatment. He also simplified the process for scheduling the preventive through development of alternate year root treatment maps.
Water Pressure Spikes in Administration Building – Dr. Lewandowski implemented continuous water pressure monitoring after failure of the building potable water system which twice caused flooding of the Administration Building. He identified the source of pressure spikes that caused pipe failure and developed recommendations for repairs.
Facilities Planning/Kitchen Remodel/Shop Remodel – Dr Lewandowski coordinated with the architect and District staff regarding facilities improvements to the Main Administration building and for expansion of office area in the former shop area. During remodeling, he assisted District inspection staff with RFIs, design questions during construction, change orders and claim review.
Engineering Solutions for Complex Water Issues