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When building a wastewater treatment plant (WWTP), municipal leaders are often baffled by their
options and associated costs. To get started, they can estimate wastewater treatment plant
construction costs at three increasingly granular levels.

Wastewater treatment plant construction costs are site-specific and influenced by a range of factors,
such as location, size, project type, and cost of labor and materials. However, the following costs will
play a role in any WWTP construction estimate.

Effluent quality and local discharge regulations determine what equipment a WWTP needs. For
example, effluent discharge containing suspended solids, metals, oils or grease requires pH
stabilization and metal removal through primary and secondary clarifiers. Removing biological
contaminants in wastewater involves specific technologies and equipment, including fixed film,
activated sludge, clarifiers, membrane bioreactors and dissolved air flotation.

Building a wastewater collection system on a greenfield site is usually less expensive than upgrading
a treatment plant. This is because a treatment plant must continue treating sewage throughout the
upgrade. To prevent service interruptions, construction must be done in a specific order and on a
tighter timeline. This puts additional constraints on contractors. They may also need to introduce
temporary treatment methods during construction to maintain the treatment standards, which
complicates the design.

Construction materials affect the overall cost of constructing a WWTP. Influent characteristics play a
large role in determining which materials are used. For high-flow, high-temperature, corrosive
and/or concentrated wastewater, high-quality stainless steel pipes are more durable than
inexpensive cast iron or painted carbon steel pipes. PVC pipes can also be a reasonable compromise
due to its corrosion resistance. However, it will not perform as well with high-temperature
wastewater. An initial upfront investment in durable materials can also reduce post-construction
costs for maintenance, repair and replacement.

The average cost of WWTP construction varies depending on the time of year and the economic
conditions at the bid time. Whether balancing operational and capital costs, solving tricky
sequencing problems or finding cost-efficient ways to meet effluent standards, partnering with a
trusted team of wastewater engineers can help municipal leaders make the right decision for their
communities.

At Fehr Graham, our team has decades of experience evaluating, planning and designing wastewater
treatment solutions for communities across the U.S. This expertise, along with a proactive approach,
has helped municipal leaders understand their options and reduce wastewater treatment plant
construction costs by:

No matter how carefully you plan the costs, wastewater treatment infrastructure is a major
investment. We know municipalities face funding gaps when building or upgrading wastewater
infrastructure. That is why we go beyond consulting on design, construction and operations. We also
help municipalities find funding to construct WWTPs in their communities.

Information on the content and format requirements of plans, specifications and engineering design
reports are listed below for the plan review of municipal, industrial and pretreatment wastewater
systems.

Section 281.41, Wis. Stats. and s. NR 108.03, Wis. Adm. Code, requires that complete final plans and
specifications for any reviewable sewerage system project to be submitted to the department. Some
reviewable projects consist of new construction or modification of sewerage system components
including sanitary sewers, lift stations, wastewater treatment plants, and effluent outfall sewers.
More information on reviewable projects can be found in the reviewable projects tab on the plan
review page.

Final plan and specification submittals shall include a design report. For treatment facilities the
report shall address hydraulic and other pollutant design loadings, sizing of treatment units, pump
capacities, and contain design calculations for major treatment units. Designs will be evaluated for
conformance with the detailed design requirements for various unit processes contained in ch. NR
110, Wis. Adm. Code. Design criteria in ch. NR 110, Wis. Adm. Code are generally premised on
particular circumstances or assumptions, and proposed units not fitting the code criteria
presumptions will be reviewed on a case specific basis. Designs shall reflect accepted engineering
practices. Allowances for code variances may be specifically addressed in the code or may be
generally requested in accordance with s. NR 110.04, Wis. Adm. Code.

Section 281.41, Wis. Stats. and s. NR 108.03, Wis. Adm. Code, requires that complete final plans and
specifications for any reviewable industrial wastewater system project to be submitted to the
department. Some reviewable projects consist of new construction or modification of industrial
wastewater system components including wastewater treatment plants, monitoring devices,
groundwater monitoring wells, and effluent outfall sewers. More information on reviewable projects
can be found the reviewable projects tab on the plan review page.

The construction of an industrial wastewater system project may not commence until a written
department approval is issued for the final construction plans and specifications. Starting
construction without an approval is a violation of s. 281.41, Wis. Stats. The penalty for such a
violation may be a forfeiture of not less than $10, and up to $5,000, for each violation, in accordance
with s. 299.97, Wis. Stats.

Prior to preparation of final plans and specifications for an industrial wastewater facility, a
conceptual design report of the proposed system may be submitted. Upon request the department
will provide written comments on the acceptability of the concept and advice regarding design
requirements.

A complete submittal of construction plans to WDNR for a proposed new or modified wastewater
system for industrial wastewater must contain an engineering design report in addition to the
treatment system plan drawings, and specifications.

In accordance with s. 281.41, Wis. Statutes and ch. NR 108, Wis. Administrative Code, plans for
wastewater pretreatment systems that discharge into publicly owned treatment works must be
submitted to the Department of Natural Resources for review and approval. Department approval
must be obtained prior to construction of a proposed pretreatment system.

The Department plan reviewers will evaluate the submittals to ensure that accepted engineering
practices are used and that the proposed system design is appropriate for the type of industry and
applicable pretreatment regulations. Reviewers will also check for suitable sampling provisions and
design features to ensure operational reliability. The Department does not have specific codified
design criteria for pretreatment systems.

Once the submittal is determined acceptable, a Department approval letter with one set of plans and
specifications (with Department approval stamp) will be mailed to the pretreatment system owner.
Copies of the approval letter will also be sent to the municipality owning the sewerage system
receiving the discharge, and the design engineer.

Wastewater: Characteristics should include information such as flow rates and key contaminants,
particularly those that are being regulated. Describe the type of wastewater to be treated (sanitary,
contact cooling, non-contact cooling, process), and identify any combined waste streams or side
streams. Describe the final discharge or use of treated wastewaters, i.e. sanitary sewer, storage for
truck hauling off-site or process recycle.

Need For Pretreatment: Briefly describe why the pretreatment system is needed and whether this
is a new system or a modification to an existing system. List the specific numerical standards the
system is designed to meet. If the wastewater is subject to federal standards, cite the applicable 40
CFR Standard or Wisconsin Administrative Code.

Description of System: Briefly describe the pretreatment system and the wastewater to be treated.
Indicate the design flows (gal/day) and key contaminants, as well as the actual flows and loading
anticipated. The plans and specifications, or the engineering report should contain a general project
location plan, and a schematic flow diagram including treatment units, monitoring devices and all
piping. Pipe contents and flow direction should be indicated.

Sludge Removal and Disposal: Describe the anticipated methods of removal, handling, and
disposal of wastewater treatment sludges and their filtrate recycle. Some sludges are considered to
be hazardous wastes and subject to special disposal regulations. Disposal of sludges on land may
require a WPDES discharge permit. It is important that the plans provide ready access for removing
sludge accumulating in the pretreatment system and provides for removal of sludge without taking
the system out of service.

Sampling: Describe the provisions made to sample the wastewater, including the pretreated
effluent flow monitoring and sampling equipment and frequency. Provisions should be made for a
representative monitoring point such as a manhole that is accessible to City, DNR, and EPA
regulatory persons.

Various processes that have been successfully developed for wastewater treatment (treatment of
industrial wastes/effluents) have been surveyed with special reference to biological treatment
including design of bioreactors. Limitations of each process, design and performance characteristics
of different kinds of bioreactors developed starting from stirred tanks to packed bed, fluidized bed,
moving bed, semifluidized bed, inverse fluidized bed, sludge bed/sludge blanket and downflow
stationary fixed film bioreactors have been highlighted. Utilization of membrane-based technology
and liquid phase oxygen technology in wastewater treatment has also been analyzed. Both aerobic
and anaerobic processes have been considered and possibilities of clubbing waste treatment with
waste utilization (production of valuable products from waste streams) have also been surveyed and
scrutinized.

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