Engineering Design and Construction Services for Northern Regional Pump Stations and Force Mains, Phase B

Northern New Hanover County is one of North Carolina’s fastest-growing regions, where new residential and commercial development has rapidly exceeded population projections. To keep pace with this surge in demand, the Cape Fear Public Utility Authority (CFPUA) needed to expand wastewater conveyance infrastructure sooner than anticipated. The utility identified the need for a new regional pump station and force main to reliably convey flows from growing communities, including Sidbury, Greenview Ranches, and other northern service areas, to the Northside Wastewater Treatment Plant.

Carollo was selected to lead the planning, design, and implementation of this critical project. Working closely with the client, the team developed a Preliminary Engineering Report (PER) that used CFPUA’s hydraulic model to confirm capacity needs, evaluate multiple sites, identify potential pump station upgrades, and determine the optimal route for a new force main. The analysis confirmed that a 13.6-million-gallon-per-day (mgd) regional pump station and a 3-mile, 24-inch-diameter force main would be required to meet future peak demands.

The new pump station design includes four variable-frequency-drive submersible pumps in a dry-pit configuration, a grinder structure, flow meter vault, pig launching and receiving stations, a backup generator, and diesel-powered maintenance pumps. The 3-mile force main is primarily PVC, with ductile iron in steel encasement at jack-and-bore crossings and HDPE at horizontal directional drilling segments. The project also incorporates over 3,000 linear feet of new water main of varying diameters, improving both system resilience and hydraulic performance.

To meet federal funding requirements tied to an American Rescue Plan Act (ARPA) grant, all survey, permitting, and design work had to be completed by January 2023. Carollo fast-tracked the project, moving from preliminary engineering through bid-ready documents in under 18 months, delivering the work on time and under budget.

Carollo continues to provide engineering services during construction and commissioning, offering both office and field support. When complete, the Northern Regional Pump Station and Force Main will provide critical capacity and reliability to one of the region’s most dynamic growth areas, supporting sustainable development and protecting water quality for years to come.