Big Creek WRF Expansion

The Big Creek Water Reclamation Facility (WRF) Expansion is Fulton County’s largest-ever capital infrastructure project, providing advanced wastewater treatment for more than 250,000 residents, businesses and institutions. The expansion upgraded the facility’s capacity from 24 million gallons per day (MGD) to 32 MGD and replaced its aging conventional treatment system with state-of-the-art membrane bioreactor (MBR) technology which dramatically improves the quality of water discharged into the Chattahoochee River, a critical water supply source and a protected trout stream. The facility was designed for gravity flow, eliminating the need for energy-intensive pumping and saving an estimated 40 million kWh over 20 years, which greatly reduces operating costs.

The project is a joint venture between Archer Western and Brown and Caldwell, who have an extensive history of working together. When the project began, Fulton County immediately decided on Progressive Design-Build (PDB) to foster early collaboration and trust with these two seasoned construction firms and other stakeholders. The PDB approach allowed for early site work even before the design reached 80% completion, which accelerated the schedule by two months and saved over $2 million. Prefabrication and modularization — including precast concrete panels — also reduced costs, and the reuse of existing infrastructure and onsite material processing avoided over $25 million in additional expenses.

Overcoming Challenges with 20 Years of Experience
Delivering a complex facility while keeping the existing plant in continuous operation required careful planning and meticulous sequencing. Navigating COVID-19 restrictions, global supply chain disruptions and inflationary pressures also significantly increased the project’s complexity. A comprehensive risk management plan and the team’s culture of trust and transparency — rooted in 20 years of working together — helped the project finish on time and within budget despite these unprecedented challenges.

The new facility enhances quality of life for plant staff and neighbors through noise and odor controls, ergonomic workspaces and improved safety features. The MBR system’s compact footprint supports future expansion to 38 MGD, ensuring the plant will meet community needs for the next 50 years while exceeding current and anticipated regulatory limits. By combining advanced treatment technology, sustainable design and DBIA best practices, the Big Creek WRF sets a benchmark for cost-efficient, environmentally responsible water infrastructure delivered using PDB.

Design-Build Team

Photos

Photo Credit: AW-BC JV