TRC

Comprehensive Services for New Multiphase Landfill

TRC’s comprehensive services for the multiple phases of Waupaca Foundry’s new landfill included an initial hydrogeologic investigation, design, permitting, and construction assistance.

Industries

Client

Waupaca Foundry, Inc.

Project Location

Tell City, IN

When Waupaca Foundry, Inc. (WFI), decided to build a new manufacturing facility to meet increased demand, they also needed to build a landfill close to the facility for the disposal of foundry byproduct (waste) materials. WFI retained TRC to help them fast-track the landfill development process, starting with evaluating the suitability for a landfill on a greenfield property offered by the local economic development corporation. TRC determined that although the site could be used for landfill development, its location next to a river, the topography, and site hydrology would make the design and obtaining state regulatory approval more complicated. This added to the challenge of permitting and constructing the landfill in time to receive foundry waste by the time the new plant became operational.

TRC’s comprehensive services for the multiple phases of WFI’s new landfill included an initial hydrogeologic investigation, design, permitting, and construction assistance. Highlights include:

  • Prepared an innovative design that included a gradient control system beneath the compacted clay liner to intercept groundwater, which allowed the liner to meet the required 3-foot separation distance to groundwater. The approved design provided WFI additional airspace within the same landfill footprint.
  • Expedited the permitting process; developed the construction plans and project manual; reviewed contractor bids; assisted with contractor selection; provided on-site construction observation and documentation and received Agency approval on the construction documentation report—all within WFI’s accelerated schedule.
  • Provided construction services for the liner and final cover systems for multiple phases of the landfill, including engineering construction plans and specifications, bid packages, on-site Construction Quality Assurance (CQA) services and soils laboratory testing to verify that the soil quality and installation methods were meeting specifications.

TRC also assisted WFI with identifying and developing a new landfill site that will become operational when the existing site has exhausted its designed disposal capacity.

The landfill provides a site life of approximately 16 years for disposal of industrial byproduct materials, and provides economic benefits for the company’s foundry operations.

  • The fast-track solid waste permitting process allowed construction of the disposal facility to be completed in time to accommodate new foundry operations.
  • The beneficial reuse of certain byproduct materials has offset somewhat the reduced landfill site life resulting from increased production at the facility.
  • The development of the landfill on land provided by a local development group promoted economic development on property unsuitable for the construction of buildings.

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