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Mansfield, Texas, is expanding the Bud Ervin Water Treatment Plant through a reported $50 million Phase V project while keeping the facility in service. The work adds up to five microfiltration/ultrafiltration membrane racks and is designed for an ultimate treatment capacity of 75 million gallons per day (MGD). Crews are sequencing isolations, tie-ins and commissioning so individual areas can be taken out of service without removing the plant’s treatment and disinfection capability.
The project addresses growth and regulatory needs, but the 75 MGD figure is an ultimate design target—not an independently measured post-commissioning result. Published sources also use different capacity baselines, so each number must be read in its original context.
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What is the Bud Ervin Water Treatment Plant Phase V expansion?
Phase V is a major treatment, pumping, electrical and controls upgrade at the plant that purifies all of Mansfield’s drinking water. The City of Mansfield describes a fully automated process supplied by Tarrant Regional Water District reservoirs, including Richland-Chambers, Cedar Creek and Benbrook. The process combines advanced ultraviolet oxidation with hydrogen peroxide, on-site sodium hypochlorite generation, pressurized membrane filtration and multiple disinfection barriers.
WaterWorld’s 2026 project report puts the existing-facility figure at 41.67 MGD and the ultimate design capacity at 75 MGD. The city’s current plant webpage lists up to 45.5 MGD of current supply and approximately 61 MGD of planned future capacity. A Jan. 23, 2023, City Council resolution described the existing plant as rated for 45 MGD, designed for an ultimate 60 MGD, and potentially capable of reaching 75 MGD through membrane improvements using existing treatment infrastructure and the distribution system. These are different dated descriptions and should not be combined into one baseline.
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How much capacity will Mansfield add?
The project’s design objective is to expand the plant from its existing operating range toward an ultimate 75 MGD. That does not mean 75 MGD has already been achieved or that the city has published independent post-project performance results.
| Figure | Source and context |
|---|---|
| 41.67 MGD | WaterWorld, 2026: existing facility figure |
| Up to 45.5 MGD | City of Mansfield current webpage: current supply |
| 45 MGD | City Council resolution, Jan. 23, 2023: existing plant rating |
| Approximately 61 MGD | City of Mansfield current webpage: planned future capacity |
| 75 MGD | WaterWorld, 2026, and the 2023 resolution: ultimate design objective |
The differing figures can reflect different definitions—such as rated treatment, current supply, planned stages or an existing-facility calculation—rather than a contradiction. The project record does not provide a final commissioning date or measured capacity after construction.
What equipment and controls are being installed?
Membrane and clarification systems
Phase V adds up to five MF/UF membrane racks. The expansion also includes high-efficiency plate settlers with hoseless sludge collectors and pressurized outside-in hollow-fiber membrane technology. Together, these systems increase treatment throughput while fitting new process equipment into an operating site.
Pumping and electrical resilience
Two new 500-horsepower vertical turbine pumps are planned—one at the Upper Pressure Plane High Service Pump Station and one at the Lower Pressure Plane station. Automatic transfer switches, redundant backup generators and additional backup power support critical processes, including on-site sodium hypochlorite generation.
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Plant-wide control integration
PLC and SCADA integration is intended to give operators better control and visibility across the expanded plant. The control work matters during staged construction because operators must see changing flow paths, equipment status and alarms as sections are isolated and returned to service.
Surveying, modeling and digital coordination
The team is using terrestrial LiDAR, low-altitude UAV photogrammetry, AutoCAD Plant 3D models, computational-fluid-dynamics and water-chemistry modeling, 3D laser scanning and virtual facility walkthroughs. These tools help coordinate new work with aging infrastructure that was partly undocumented, reducing the chance that a new connection conflicts with an unrecorded pipe, structure or process constraint.
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The answer is disciplined sequencing rather than a single construction trick. WaterWorld reports a 16-step sequence governing shutdowns and system transitions. Each affected section can be isolated, connected, tested and placed back into service while other treatment trains continue operating.
1. Schedule the highest-risk tie-in for low demand
A new 48-inch membrane-filtrate inlet to Clearwell No. 1 was limited to a 45-day construction window during the low-demand winter months. Choosing a period of lower water use provides more operating margin if a process area is temporarily unavailable.
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2. Connect active pipelines without draining the system
Crews hot-tapped active 30-inch and 54-inch raw-water pipelines to connect new recycle piping. Hot tapping allows a connection to be made while a pipeline remains pressurized and in service, avoiding a full plant shutdown for that work.
3. Preserve disinfection throughout the sequence
WaterWorld states that “At no point during construction was the plant without chlorination capabilities.” In practical terms, the sequence treated chlorination as a continuously protected function while other systems were isolated or switched over.
4. Return each transition to a controlled operating state
The project approach required individual sections to be tested and returned to service before the next transition. That limits the number of simultaneous unknowns and gives operators a defined fallback condition if a connection or control change does not perform as expected.
Why does Mansfield need the expansion?
The City Council’s Jan. 23, 2023, resolution says operating trends and regulatory requirements indicated that additional treatment capacity was needed to meet Mansfield’s growth demands. The plant is also described by the city as a regional water supplier, so capacity planning must account for both local growth and the distribution system that moves treated water beyond the plant.
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The 2023 resolution’s statement that membrane improvements could support 75 MGD using existing treatment infrastructure and the distribution system explains why Phase V focuses on membrane racks, pumping, controls and resilience rather than an entirely new treatment site. It does not establish that the full design capacity is currently available.
How is the project being delivered?
The project uses a Construction Manager At-Risk (CMAR) approach involving the City of Mansfield, Archer Western Construction and Plummer Associates. On Jan. 23, 2023, the city authorized Plummer’s Phase V design contract. The scope covers mechanical, electrical, instrumentation, structural, architectural, HVAC and civil design, along with CMAR support for value engineering, equipment procurement, project management and construction.
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Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What is known—and not yet established—about results?
Published project information supports the reported scope, the 16-step construction sequence, the 45-day Clearwell No. 1 tie-in window and the claim that chlorination capability was maintained. It does not provide a definitive completion or final commissioning date, independently measured post-commissioning capacity, reliability data or post-project water-quality results. The 75 MGD value should therefore be treated as the project’s ultimate design figure.
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Frequently Asked Questions
Why were winter months chosen for the Clearwell tie-in?
The reported work window was scheduled during low-demand winter conditions. Lower demand generally gives operators more flexibility while a major process connection is isolated, although the published project account does not quantify a specific reserve margin.
What does hot tapping accomplish on a raw-water pipeline?
Hot tapping permits a new branch or connection to be made on an active, pressurized line. For this project, it allowed recycle piping to connect to 30-inch and 54-inch raw-water pipelines without taking those pipelines—and the plant—out of service.
Does a 75 MGD design mean Mansfield can deliver 75 MGD today?
No. The 75 MGD number is an ultimate design objective reported for Phase V and in the 2023 council resolution. The available project information does not establish a final commissioning date or independently measured operating capacity at that level.
Why use LiDAR and 3D models on an older treatment plant?
The project team encountered aging infrastructure that was partly undocumented. LiDAR, photogrammetry, laser scanning and Plant 3D models create a coordinated record of existing conditions so new equipment and piping can be designed around actual geometry rather than incomplete drawings.
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