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Sewer Line Expansion – Gary/Chicago Airport

Located in Indiana

  • Capability
    • Underground Infrastructure
  • Completion 2025

Project Overview

After months of planning, preparation, and delays, we began construction of a new sewer line in support of the Gary/Chicago International Airport expansion in Gary, Indiana. The project represents the first phase of a $24 million infrastructure investment designed to expand the airport’s cargo logistics sector.

Key Highlights

The sewer expansion was designed and managed by the U.S. Army Corps and was the first time our team worked as part of a public-private partnership. High groundwater levels and broad scale gave the job a level of complexity that went far beyond that of a typical sewer pipe installation. The crew was responsible for safely installing nearly 2,000 feet of sewer line to specifications.

Explore Project Details

Project Scope of Work Included:

  • Continuous Dewatering of Over 1,000 Feet of Ditch due to High Groundwater Levels
  • Installation of 900 Trench Wellpoints at 25-Foot Depths to Manage Water Removal
  • Excavation, Removal, and Hauling of Over 8,000 Tons of Sandy Trenching Spoil
  • Lining, Backfilling, Compacting, and Testing of Pipe Trenches with Compact Stone
  • Installation of 12 Concrete Sewer Structures for Every 300 Feet of Pipe
  • Nearly 2,000 Feet of Sewer Pipe Installation at Depths Up to 20 Feet

Challenges and Results

The scope of excavation on this project required some of our biggest equipment and excavators to safely install the large trench boxes that ensured crew protection. At times, ten large trench boxes were needed on site, and prior to their removal, each stone backfill layer was required to be compacted and tested in 6-foot lifts. Final piping and electrical connections were made in the field to ensure proper alignment and operation of the system.

Sewer installation, which began in October 2024 and was successfully completed in March 2025, includes a new system and structures designed to carry flow to a 22-foot grinder pump station.

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Gary Sewer Gallery 1
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Project Overview

After months of planning, preparation, and delays, we began construction of a new sewer line in support of the Gary/Chicago International Airport expansion in Gary, Indiana. The project represents the first phase of a $24 million infrastructure investment designed to expand the airport’s cargo logistics sector.

Key Highlights

The sewer expansion was designed and managed by the U.S. Army Corps and was the first time our team worked as part of a public-private partnership. High groundwater levels and broad scale gave the job a level of complexity that went far beyond that of a typical sewer pipe installation. The crew was responsible for safely installing nearly 2,000 feet of sewer line to specifications.

Explore Project Details

Project Scope of Work Included:

  • Continuous Dewatering of Over 1,000 Feet of Ditch due to High Groundwater Levels
  • Installation of 900 Trench Wellpoints at 25-Foot Depths to Manage Water Removal
  • Excavation, Removal, and Hauling of Over 8,000 Tons of Sandy Trenching Spoil
  • Lining, Backfilling, Compacting, and Testing of Pipe Trenches with Compact Stone
  • Installation of 12 Concrete Sewer Structures for Every 300 Feet of Pipe
  • Nearly 2,000 Feet of Sewer Pipe Installation at Depths Up to 20 Feet

Challenges and Results

The scope of excavation on this project required some of our biggest equipment and excavators to safely install the large trench boxes that ensured crew protection. At times, ten large trench boxes were needed on site, and prior to their removal, each stone backfill layer was required to be compacted and tested in 6-foot lifts. Final piping and electrical connections were made in the field to ensure proper alignment and operation of the system.

Sewer installation, which began in October 2024 and was successfully completed in March 2025, includes a new system and structures designed to carry flow to a 22-foot grinder pump station.

Previous
Gary Sewer Gallery 1
Gary Sewer Gallery 2
Gary Sewer Gallery 3
Gary Sewer Gallery 4
Next
Previous Gary Sewer Gallery 1 Gary Sewer Gallery 2 Gary Sewer Gallery 3 Gary Sewer Gallery 4 Next
Previous 0 1 2 3 Next