Rocky River Regional Wastewater Treatment Plant Phase 3 Expansion (Progressive Design-Build (PDB))

The Rocky River Regional Wastewater Treatment Plant (RRRWWTP) Phase 3 Expansion addressed the urgent need to increase treatment capacity and improve reliability for one of North Carolina’s fastest-growing service areas. Operated by the Water & Sewer Authority of Cabarrus County (WSACC), the facility’s expansion was essential to meet the region’s increasing demands and ensure long-term operational resilience. Originally projected for completion in 2027, WSACC set an ambitious goal to deliver critical capacity sooner — ultimately completing the project three years ahead of schedule thanks to a phased implementation strategy with Progressive Design-Build (PDB).

PDB enabled WSACC, Crowder Construction and Brown and Caldwell to form a fully integrated team at a very early stage. This early engagement and planning allowed the team to procure long-lead items — such as electrical gear and piping — before design was finalized, mitigating delays and later, avoiding post-COVID supply chain risks. Design and construction overlapped wherever feasible, while prefabrication, modular assemblies and strategic sequencing reduced field labor and minimized operational disruptions.

Delivering Innovations and Savings
Some of the major upgrades to this water treatment plant include improved nutrient removal to protect downstream waterways, conversion from high-purity oxygen to diffused aeration for greater energy efficiency, and safety-driven upgrades such as enclosed chemical storage, improved ventilation and redundant power systems. These enhancements not only safeguarded operators and the public but also reduced chemical use and energy consumption, aligning with WSACC’s sustainability goals. Where possible, existing infrastructure was rehabilitated and reused, reducing capital costs, construction waste and environmental impact further.

The phased delivery approach, disciplined cost management and a shared-savings financial incentive structure returned nearly $8.5 million to WSACC which helped maintain stable utility rates for residents. Community engagement, including outreach and education, reinforced public trust while the added capacity immediately relieved water capacity constraints.

By utilizing design-build best practices, the RRRWWTP Phase 3 Expansion delivered a high-performing facility years ahead of schedule and under budget. This project stands as a model for how PDB can overcome challenges, accelerate delivery and provide lasting environmental, economic and community benefits.

Design-Build Team

Photos

Photo Credit: Crowder Construction