Phos Acid Pond Water Return Trench and Sump Project

Aurora, NC

Project Description:

Trader Construction, in partnership with Carolina Engineers, successfully completed a complex design-build project for an industrial client requiring a high-capacity service water return trench and sump collection system. Engineered to manage flows of up to 120,000 gallons per minute, the system featured a concrete trench and sump lined with polypropylene for its superior chemical resistance and durability under extreme temperatures reaching 195 degrees Fahrenheit. The design included a maintainable and partially isolatable trench system, allowing for uninterrupted operation of the Phosphoric Acid Plant throughout the 2.5-year construction timeline. With trench depths reaching 12 feet, the project involved phased replacement of the existing trench and pump pit system, removable concrete lids capable of supporting crane traffic, and multiple shoring methods—including sheet piling, soldier pile and lagging, and trench boxes. Intricate dewatering, bypass pumping, and working within tight site constraints near active plant operations made this one of the most demanding yet successfully executed projects in Trader’s portfolio.