Design and Construction of a Modernized Industrial Wastewater Treatment Facility (Bioplant) at Radford Army Ammunition Plant (RFAAP)

STATEMENT OF WORK Modernized Bioplant Design-Build for Radford Army Ammunition Plant (RFAAP) INTRODUCTION Objective To design, construct, and successfully commission, a modernized industrial wastewater treatment facility (referred to as the Bioplant) capable of treating the full volume and variety of Radford Army Ammunition Plant (RFAAP) industrial wastewater influent while meeting or exceeding the environmental permit requirements. The design and engineering work on this contract will confirm the technical requirements, select the optimal treatment technology, refine siting, obtain required permitting, and produce Professional Engineer (PE)-sealed Issue for Construction (IFC) design documents for use in constructing the facility. Construction and commissioning will then produce a turnkey facility for handoff to the Operating Contractor after ensuring appropriate training and licensing of facility operators. Background RFAAP was built in the 1940s to support ammunition demand during World War II. Since then, RFAAP has become a national asset as the last remaining CONUS Government owned facility capable of manufacturing nitrocellulose (NC), nitroglycerin (NG), single-base, multi-base, and solventless propellants. The wastewater generated during the manufacture of these propellants must be treated in accordance with RFAAP’s permits prior to release to the New River. The legacy RFAAP Bioplant was constructed in the 1980s and is beyond its useful service life, located within the 100-year floodplain, and poses a single point failure for plant operations. It has experienced numerous environmental permit violations and a recent shutdown during Hurricane Helene in 2024. Funding has been accelerated to FY26 to address this critical risk. The existing RFAAP Bioplant treats industrial wastewater generated by propellant manufacturing. This wastewater contains solvents and propellant residue (i.e., any solid, dissolved, or suspended energetic material remaining in process wastewater as a byproduct of manufacturing, loading, or packing operations) that require remediation prior to discharge to the New River. This discharge is regulated by a permit issued by the Virginia Department of Environmental Quality (VDEQ) under the Clean Water Act. The Virginia Pollutant Discharge Elimination System (VPDES) permit identifies pollutants of concern and establishes discharge limits RFAAP must adhere to. Over the years, the current facility has had issues consistently treating the wastewater which have resulted in permit violations. During a 16-month period, there were 14 violations that resulted from three separate incidents. While there are multiple causes, the recent violations were largely related to biochemical oxygen demand (BOD) and chemical oxygen demand (COD) limitation violations and failure of Whole Effluent Toxicity (WET) testing. Boundaries The Bioplant shall receive wastewater influent from the Industrial Wastewater Collection system via pump station PS 906-17 at the headworks which is outside the boundary of the program. After treatment, water shall be discharged to the New River. Pre-treatment shall be co-located with the primary treatment technology. Remote, point-source, production facility pre-treatment is outside the scope of the project. Figure 1: Legacy Bioplant Operations The design will account for connection to existing utilities to make tie-in connections only, but the utilities upstream of the Modernized Bioplant facility will be outside the bounds of this project. The approximate location for the Bioplant is shown in Figure 2 and will need to be finalized during the design phase to ensure compliance with explosives safety site (ESS) requirements when developing and ultimately obtaining Department of War Explosive Safety Office (DWESO) approval of the final explosive safety site plan (ESSP). Execution Strategy This program is divided into two phases: Phase I – shall include the design charrette, design development and package submittals, analysis, Pilot/Prototype Study for down-selected technology, site investigation, permitting (VDEQ and ESSP), surveys, risk analyses, procurement of Long Lead Equipment (LLE), and cost estimates; Phase II – shall produce a complete Issue for Construction (IFC) design package which will be used for site preparation, remaining equipment and material procurement, and construction and commissioning of the modernized Bioplant. Turnover to RFAAP shall be accepted accomplished after successful prove-out and commissioning of the facility. Figure 2: Approximate proposed location for modernized Bioplant APPLICABLE DOCUMENTS (Contractor shall comply with applicable aspects of the following documents. These are not considered holistically compliance documents. The following section headers are for reference and organization only and are not intended to limit the application of any documents specifically to its header). Federal and Military Regulations and Specifications Construction Standards All applicable and most recent editions of the United Facilities Criteria (UFC) and Unified Facilities Guide Specifications (UFGS) Unified Facilities Criteria (UFC): UFC 1-200-01: DoD Building Code: General Building Requirements. API 653 – Tank Inspection, Repair, Alteration, and Reconstruction (access and maintenance provisions). ASTM A36, A325, A572 & A992, Standards for structural materials and load ratings ASTM E1557 – Standard Classification for Building Elements and Related Sitework – UNIFORMAT II ASTM E2083 – Standard Classification for Building Construction Field requirements, and Office Overhead & Profit Standard Classification MIL-STD-961 for Building Elements and Related Sitework Life Cycle Management DoD Risk, Issue, and Opportunity (RIO) Management Guide for Defense Acquisition Programs, September 2023 MIL-HDBK-502A – Product Support Analysi…