Strengthening Fargo’s Water Infrastructure for the Future

In Fargo, North Dakota, where steady population growth and a commitment to watershed integrity underscore the need for clean water, a significant infrastructure overhaul is in motion.

Through a $124 million expansion and modernization effort, the Fargo Regional Water Reclamation Facility (Figure 1) is set to more than double its capacity, reaching over 30 million gallons per day. This ambitious project, part of Fargo’s long-term strategic planning, addresses both the city’s increasing demands and the need to modernize aging systems. It also embodies Fargo’s commitment to environmental responsibility and sustainable community growth.

“The scale is massive – this is a once-in-a-working career kind of project,” said Mark Miller, Fargo Wastewater Utility Superintendent. “We know we’re not just building for today. It’s an opportunity to safeguard the future."

Engineering a New Era

This multi-year project combines new construction and major structural improvements, including a substantial amount of structural concrete (Figure 2) for a new Integrated Fixed-Film Activated Sludge (IFAS) building and other facilities. It also involves the rehabilitation of existing infrastructure, extensive excavations and expanded piping to support a larger headworks facility, along with non-slip resinous flooring for improved safety.

Fargo’s growth has driven this ambitious initiative. Since 2018, the city’s facility has also treated wastewater from neighboring West Fargo, allowing that municipality to retire its open-air lagoon system and improve local air quality.

Serving more than 180,000 residents, Fargo’s facility relies on 67 lift stations that channel mostly residential wastewater into the treatment system. After filtering out large solids and grit, the water undergoes biological filtration, aeration and clarification processes – followed by UV disinfection before release into the Red River or into stabilization ponds.

Reducing nutrient levels is vital to the Red River Valley ecosystem, benefiting downstream users impacted by agricultural runoff and helping to sustain the region’s water quality.

“There is an economy of scale from having one facility that benefits everyone. Every gallon of water that flows down a drain ends up at our facility,” said Miller. “This expansion fulfills our duty to treat water properly and return it to the environment in the condition it needs to be.”

Adaptive Approaches

Aligning key stakeholders has been critical to advancing the project.

When the specified coatings supplier encountered pricing and supply chain challenges, Fargo-based Protech Contracting Services Inc., the project’s applicator, pivoted to Sherwin-Williams Protective & Marine for coatings solutions. This switch was seamless, as Sherwin-Williams products met the project’s stringent requirements for reliability, compatibility and availability – essential factors for maintaining the timeline and minimizing delays.

“It wasn’t just about changing products – it was about finding a solution that worked for everyone involved, while ensuring both reliability and cost-effectiveness,” said Dale Mulvaney, President of Protech. “We’ve adapted to different specifications countless times. When the switch happened to Sherwin-Williams, we hit the ground running. There were no delays, no hiccups – just a seamless transition that kept the project on track.”

Sherwin-Williams has provided essential technical support to Protech throughout the project, offering on-site assistance and expert guidance to guide precise product application and adherence to specifications.

“Having a partner at the ready, with support and expertise, gives us confidence when taking on a project of this magnitude,” added Mulvaney.

This collaboration has been central to the project’s success, especially given its complexity. An intricate coating schedule – dictated by tight timelines and limited space – has demanded close coordination with general contractor PKG Contracting and project engineer Apex Engineering Group. 

Together, the teams have navigated challenges such as managing the concurrent needs of multiple trades, maintaining strict schedules, adapting to shifting project priorities and applying coatings without disrupting plant operations.

“We have embraced careful planning together, in a common effort,” said Mulvaney.

Protection Precision

The Fargo project required coating various surfaces, from concrete structures and piping (Figure 3) to equipment, walls and floors. Techniques varied by surface, with high-pressure airless spraying used for expansive areas and hand-rolling reserved for complex systems and confined spaces.

“In every infrastructure project, the details matter, and the right protective coatings are central to the durability and success of this one,” said Mulvaney. “The right coatings ensure the facility’s long-term performance and sustainability.”

To create non-slip flooring in high-traffic areas, the team used a combination of broadcasting and back-rolling techniques, adding sand to both mid-coat and topcoat layers. This method provided a robust, abrasion-resistant surface that’s also easy to clean and chemical-resistant.

In the new IFAS facility, Protech applicators worked in four-person teams to coat the top seven feet of aerobic tanks that face exposure to gases, applying Dura-Plate® 2300 as a base coat followed by Dura-Plate® 6000 for top protection against chemical exposure, corrosion and leaks.

Other critical components – such as the return activated sludge splitter box, IFAS splitter box, waste pump station wet well, valve vault and several manholes – also received a base layer of Dura-Plate 2300 and a top layer of Dura-Plate 6000 for durable protection. Protech used a mortar sprayer for applying Dura-Plate 2300 on larger areas, followed by high-pressure spraying of Dura-Plate 6000, while smaller or hard-to-reach areas were coated by hand, reducing the need for containment and cleanup.

Concrete surfaces exposed to hydrogen sulfide gases, chemicals and abrasions – such as outdoor basins (Figure 4) – received a multi-layer system consisting of a primer, Sher-Glass® FF (a glass flake-reinforced epoxy) as the mid-coat and a urethane topcoat for areas visible to the public.

General piping not exposed to gases (Figure 5) was coated with Macropoxy® 646 epoxy topped with a urethane coat to guard against corrosion and chemicals. Protech prepared new and existing concrete surfaces by blasting to achieve optimal adhesion.

For outdoor equipment exposed to UV light, the team applied Hi-Solids Polyurethane 250 – chosen for its durability, gloss and color retention – to provide heavy-duty protection against the elements.

Finally, for metal and fiberglass surfaces like tanks and ducting, Protech used a multi-coat system with Corothane® Mio-Zinc Primer, Macropoxy 646 and Acrolon™ Ultra for comprehensive corrosion resistance, UV protection and an enhanced appearance.

“We needed coatings that last long, delaying the next maintenance cycle and extending asset longevity by protecting our investment,” said Mulvaney. “We chose durable coatings offering long-term protection against hydrogen sulfide, harsh environmental exposure and spray paint.”

Watershed Achievement

The city’s facility has doubled its capacity – now surpassing clean water standards and significantly reducing pollution. Wastewater now exceeds regulatory requirements, with ammonia-nitrogen levels reduced by 30% and phosphorus levels by 80% before being released into the Red River.

“Our effluent numbers have never been better. The quality of the treated water we’re releasing is exceptionally high,” said Miller. “We’re removing more waste before it reaches the watershed of the river, which improves overall water quality.”

The project earned top recognition in the 2023 Sherwin-Williams Impact Award, which highlights outstanding projects using Sherwin-Williams Protective & Marine’s high-performance coatings and linings.

“We take great pride in playing a role in helping make clean water more accessible and improving how wastewater is processed,” said Mulvaney. “Coatings will ensure this vital infrastructure stands the test of time.”

Although major elements of the project are complete, construction is set to continue through 2025. The project stands out not only for its scale but for the precision in coordination, product selection and expert implementation.

As Fargo expands, the upgraded water reclamation facility will boost capacity and operational resilience, supporting the city’s environmental goals and public health needs. 

“Coatings play a significant part the work we do to improve quality of life in our region,” said Miller. “They’re more than just a protective layer – they represent a long-term commitment to the community, ensuring that our infrastructure remains strong and reliable for years to come.”

ABOUT THE AUTHOR
Paul Trautman has 30 years of experience in the paints and coatings industry working in various capacities, including 20 years with Sherwin-Williams Protective & Marine, where he is currently Market Director of the Water Infrastructure segment. Trautman has authored technical papers related to protective coatings and presented educational programs for the Society of Protective Coatings (SSPC) Coatings+ Conference and regularly hosts educational luncheons for municipalities, industrial facility owners and consulting engineering firms. Contact: Paul.Trautmann@sherwin.com

Figure 1. The City of Fargo is expanding its wastewater reclamation facility to boost capacity – now capable of processing over 30 million gallons per day – while improving efficiency and sustainability.

Figure 2. This multi-phase, multi-year project features key upgrades – including the construction of a new IFAS building, extensive excavation work, expanded piping systems and safety enhancements.

Figure 3. For complex piping networks and confined spaces, applicators employed specialized hand-rolling techniques for precise coating applications.

Figure 4. Outdoor concrete basins, designed for grit and sludge removal, were protected with a multi-layer coating system – featuring a primer, glass flake reinforced epoxy and a durable urethane topcoat.

Figure 5. For proper adhesion, applicators blasted both new and existing concrete surfaces. Piping not exposed to gases received a protective layer of Macropoxy® 646 epoxy, followed by a urethane topcoat, to promote corrosion resistance and durability.