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Key Insights

Quick Facts

  • Name: Carrollton Water Plant Electrical Substation Project
  • Location: New Orleans, Louisiana
  • Customer: Cycle Construction Company, LLC
  • Client: Sewerage & Water Board of New Orleans
  • Size: Approximately 8 acres
Challenge: The project required stabilizing land for a new electrical substation in a location with poor soil conditions and significant water intrusion, all while minimizing lateral forces on nearby active water basins.
How Arcosa Helped
  • Our Solution: Arcosa Lightweight provided 20,000 cubic yards of lightweight aggregate to stabilize the substation site, addressing issues with compressible soil and lateral pressure on adjacent structures.
  • Why Lightweight Works: The lightweight aggregate reduced the weight and lateral forces exerted on the surrounding water tanks and basins while maintaining stability, even in wet conditions.

Final Results

  • The new electrical substation was successfully constructed, stabilizing the site and modernizing the power supply for the water and sewer systems, reducing the risk of outages.

Key Quote

Lightweight aggregate fit the bill perfectly. It reduced lateral forces and helped stabilize the site without compromising the surrounding structures.” — Ethan Oddo, Project Manager, Cycle Construction

Context:

  • Considerations: The project was part of New Orleans’ broader effort to transition away from aging steam-powered turbines, improving the reliability of essential services.
  • Lessons Learned: Lightweight aggregate offers an effective solution for challenging geotechnical applications, particularly in areas prone to water intrusion and compressible soils.
Explore Further

Contact Arcosa to learn more about how lightweight aggregate can improve geotechnical stability in your projects.

Modernizing Infrastructure at the Carrollton Water Plant

The Carrollton Water Plant, a critical infrastructure asset for the east bank of Louisiana’s Orleans Parish, supplies around 135 million gallons of treated water daily to homes across New Orleans. Arcosa Lightweight stabilized the land for a new dedicated electrical substation, which now powers the modernized water and sewer systems. This project ensures long-term reliability and performance for one of the region’s most essential utilities.

Cycle Construction Company, LLC, a family-owned general construction firm in Kenner, LA, handled the geotechnical phase. Project Manager Ethan Oddo explains, “Our task was to provide a blank slate. The site previously housed two large holding tanks, which had been abandoned. We removed all structures, walls, and slabs, then filled the area to grade with compacted materials. We used sand at the bottom, followed by two to three feet of Arcosa’s lightweight aggregate, and capped it with a foot of #610 limestone.”

Lightweight Plays Its Part

Cycle Construction used up to 20,000 cubic yards of Arcosa’s 3/16” fine granular lightweight aggregate to elevate the site. The lightweight aggregate reduced the density of the compacted fill, minimizing the impact of weight and lateral forces on nearby water basins.

“On three sides of the basin, we had active drinking water basins and tanks,” says Oddo. “Lateral forces couldn’t be too high, or we’d risk cracking the walls. Lightweight aggregate fit the bill perfectly.”

Cycle’s Civil Superintendent Dennis Grantham also praised the aggregate’s performance. “I had only seen lightweight aggregate used for landscaping, but its geotechnical performance exceeded my expectations. I thought compaction would be challenging, but we achieved great results,” says Grantham. “I expect to see more contractors using lightweight aggregate because of how well it works.”

Grantham also commended Three C’s Trucking: “They do an excellent job. When the material is close at hand, we can place 2,000 to 3,000 yards a day. They’re fantastic at making things happen.”

Arcosa Lightweight also helped solve water intrusion issues on the site. “We had a lot of water on-site,” says Oddo. “But where we used lightweight aggregate, especially combined with geotextiles, we haven’t seen any issues with water intrusion.”

Increased Reliability

The new substation is a key part of New Orleans’ Sewerage & Water Board modernization, transitioning away from outdated steam-powered turbines to modern energy sources. This upgrade enhances the system’s reliability, especially during severe weather events.

“It’s critical to keep the water plant operational,” says Oddo. “We get hit by hurricanes and floods, and we lose power several times a year. When that happens, the Sewage and Water Board loses power, leading to low water pressure and boil water notices. This project was essential to solving that problem.”

According to a report from Entergy New Orleans, the project aims to increase reliability by routing power directly from the transmission system, which is less prone to outages. The new substation also provides the increased capacity needed to serve drainage pumps previously powered by aging infrastructure.

Lunch and Learns: Sparking Innovation

The Carrollton substation project originated from one of Arcosa’s Lunch and Learn sessions. Arcosa’s Bill Wolfe explains,

“We host these sessions for offices unfamiliar with our products. We introduce Arcosa Lightweight, explain its benefits, and share ideas on how it can be used. That’s how the Carrollton project came about.”

For information on upcoming programs or to schedule a session for your team, call 1-800-342-LITE.