Freeport Adds Capacity Without Disrupting Service

A new 1.6 MGD wastewater treatment plant replaced aging infrastructure while maintaining service during construction

Freeport’s existing wastewater treatment facility was approaching the end of its useful service life and experiencing structural problems. The city needed a new plant that could provide reliable wastewater treatment capacity while allowing the existing facility to remain operational during construction.

AUC Group constructed a new 1.6 million gallon per day (MGD) steel concentric wastewater treatment plant alongside the existing facility, using its established concentric configuration and conventional activated sludge process. The parallel-build approach allowed Freeport to maintain wastewater treatment service throughout construction.

Scaling a Proven Treatment Configuration

The Freeport project demonstrated AUC’s ability to apply its established conventional activated sludge process and concentric treatment configuration to a larger-capacity installation. The 1.6 MGD plant featured an 80-foot clarifier and a 130-foot outer wall incorporating aeration and chlorine contact treatment chambers.

Moving to an 80-foot clarifier required a structural transition from a bridge-supported to a pier-supported design to maintain integrity at the larger diameter. The treatment process, operating characteristics, and maintenance requirements remained consistent with AUC’s established clarifier systems. While fabrication and installation methods remained largely unchanged, the larger structural components required more substantial material handling and heavier lifting equipment.

Building Alongside an Operating Facility

The new plant was constructed beside Freeport’s existing wastewater treatment facility, which remained operational throughout construction. This approach allowed the city to maintain essential municipal wastewater treatment service while the replacement plant was built.

Working alongside an active facility required coordination of construction staging, site access, lifting operations, and safety. Despite the larger structural components involved, AUC completed the project from mobilization to commissioning in approximately six months.

Why the Project Mattered

The Freeport project demonstrates AUC’s ability to deliver larger-capacity wastewater treatment infrastructure while maintaining service at an existing facility. By constructing the new 1.6 MGD plant alongside the operating system, AUC allowed the city to continue wastewater treatment throughout construction.

The project also demonstrated AUC’s ability to scale its concentric treatment configuration to larger municipal applications. The 80-foot pier-supported clarifier and 130-foot outer wall accommodated the plant’s larger capacity while retaining AUC’s established conventional activated sludge treatment process.

For municipalities facing aging infrastructure, structural concerns, or increasing wastewater treatment needs, Freeport demonstrates how a new facility can be constructed alongside an existing plant without interrupting essential service.

The result is a new 1.6 MGD wastewater treatment plant that demonstrates AUC’s larger-capacity capabilities and its ability to deliver replacement infrastructure while maintaining ongoing operations.

Need to replace aging infrastructure or expand treatment capacity without disrupting service? Contact AUC to discuss your project.