Tom Taylor Regional WTP 72-in. Parallel Pipeline Extension

Lewisville, Texas


Owner Upper Trinity Regional Water District

Lead Design Firm/Civil/MEP Plummer Associates Inc.

GC Archer Western Construction LLC

Structural JQ

Working under a construction manager at-risk delivery method, Archer Western Construction led a $39-million effort to add much needed capacity and redundancy to the Upper Trinity Regional Water District. The scope included installation of a 19,000-linear-ft 72-in. pipeline from the Tom Taylor Regional Water Treatment Plant to the district’s Stone Hill Pump Station. The new pipeline runs parallel to an existing single 48-in. pipeline, which, at the time, conveyed more than 95% of the potable water along that alignment.

As the main pipeline of potable water, the existing 48-in. pipeline could not be disturbed and had to be continually protected. Shutdowns for connections were minimized, conducted during low-flow periods to avoid service disruptions. The design team addressed schedule constraints by fast-tracking the design and prioritizing segments while collaborating with Archer Western on how to deliver the project. Typically, detailed design for a project of this scope would have taken 16 to 20 months, according to the submitter. By prioritizing key crossings, pipes and equipment in parallel with easement acquisition and early procurement, the team provided full design, permitting and easement acquisition within 10 months of the notice to proceed.

Tom Taylor Regional

Photo courtesy of Archer Western Construction

The project covered four miles of pipeline through a busy city, intersecting existing business parking lots, apartment lots, schools and, in some cases, passing up to 12 ft from residential homes. The scope included 11 tunnels with three railroad crossings and one major highway crossing as well as water and utility crossings. Every employee had to obtain the required certification to operate within proximity of railroad tracks legally and safely.

When working within 25 ft of railroad tracks, a flagger had to be on site to alert workers of any potential railroad traffic and ensure that the track was never compromised. Archer Western packaged the railroad flagging separate from other work installation packages, which reduced bidding costs and minimized installation interruptions.

Started in July 2020 and completed in April 2022, the project was finished on schedule and at budget.