Overview

A coastal municipality needed to replace the electrical and control system at a critical sewage influent lift station. Traditional design‑bid‑build methods risked prolonged schedules and unforeseen costs. The city opted for a progressive design‑build approach, partnering with a controls integrator and construction team to deliver the project through collaborative phases. This method allowed the team to resolve issues early, reduce unknowns and maintain continuous lift station operation.

Challenge

• Replace outdated electrical and control systems without interrupting sewage pumping
• Accelerate project delivery to minimize service disruption
• Reduce cost uncertainty and address design issues before construction
• Ensure new systems integrate seamlessly into existing SCADA
• Align design with municipal standards and stakeholder expectations

Solution

Using a progressive design‑build delivery method, the integrator worked alongside the municipality and construction contractor from the outset. During the initial phase, they developed the design, performed site assessments and collaborated with stakeholders to resolve potential issues. Subsequent phases focused on implementing the design, including installation of new PLCs, control panels, telemetry and electrical switchgear. Continuous owner involvement ensured that procurement and contracting decisions reflected the city’s priorities. The phased approach allowed accurate cost determination and kept the lift station operational throughout the project.

Technical Scope

• Design and installation of new PLC‑based control system and operator interface
• Replacement of electrical switchgear and power distribution equipment
• Integration with existing SCADA/telemetry for remote monitoring
• Pump control logic development and commissioning
• Collaborative design reviews and phased implementation

Results

The progressive design‑build project delivered a modern, reliable electrical and control system ahead of traditional schedules. By resolving design uncertainties early, the team minimized change orders and ensured cost transparency. Continuous lift station operation was maintained, and the new controls provided operators with improved visibility and remote access. The project demonstrated that collaborative delivery methods can enhance efficiency and reduce risk for critical infrastructure upgrades.

Key Advantages Delivered

• Faster project delivery compared with traditional methods
• Reduced cost risk through phased design and early problem resolution
• Improved reliability and remote monitoring of lift station operations
• Enhanced collaboration between owner, engineer and contractor
• Scalable control architecture for future upgrades

Closing Summary

By leveraging progressive design‑build, the municipality modernized its sewage lift station with minimal disruption and maximum collaboration. The new electrical and control systems enhance reliability, provide remote visibility and set a precedent for efficient infrastructure upgrades.

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