Project Overview
The City of Stephenville initiated the Eastside Sewer Interceptor – Phase I to address growing wastewater demands, aging infrastructure, and regulatory compliance requirements. This project was designed to expand system capacity, enhance reliability, and replace outdated pipelines to support the city’s long-term development. The total contract value was $21,956,762, with a well-managed budget and change orders accounting for less than 1% of the original contract amount. The project involved significant trenching (25-60′ deep), tunneling, and large-diameter pipe installations to improve wastewater conveyance efficiency.
The Problem
Insufficient Sewer Capacity: Existing pipelines could not accommodate peak flow demands, increasing overflow risks.
Aging Infrastructure: Deteriorating sewer pipes required frequent maintenance and posed structural risks.
Environmental & Regulatory Compliance: Upgrades were necessary to align with state wastewater regulations.
Our Solution
Collaborating closely with city engineers, we implemented a robust plan to replace deteriorating infrastructure with over 16,200 linear feet of large-diameter Fiberglass Reinforced Pipe (FRP). We strategically selected FRP in 30-inch, 36-inch, and 48-inch sizes to ensure superior corrosion resistance and decades of structural reliability.
The project required extensive technical execution, including trenching at depths of up to 60 feet. In high-traffic and environmentally sensitive areas, we utilized trenchless boring and jacking operations with 48-inch to 60-inch steel casings to minimize surface disruption. Additionally, we installed 41 custom FRP manholes designed to withstand fluctuating loads over the long term.
Where the work impacted community spaces, we provided full restoration through trail reconstruction and hydromulching for erosion control. Through diligent safety coordination and constant communication with city stakeholders, we successfully delivered this critical infrastructure upgrade on schedule and within scope.
The Results
The completion of the Eastside Sewer Interceptor marks a turning point for Stephenville’s infrastructure. The upgraded system has increased capacity by 40%, providing a critical buffer for future growth while eliminating the chronic overflow risks that previously threatened regulatory compliance.
By utilizing durable FRP materials, we have extended the system’s operational lifespan by an estimated 50 years, significantly reducing long-term maintenance burdens. This project also serves as a model for fiscal responsibility; with a total contract value of $21.96 million, change orders accounted for less than 1% of the original estimate.
Ultimately, this project highlights the value of strategic execution and premium materials. Stephenville now possesses a resilient, future-ready interceptor system built on a foundation of engineering excellence.
