Romtec Utilities partnered with Brown & Caldwell to design and deliver a specialized paint wastewater lift station at an aircraft hangar at a regional aviation facility in Wisconsin. This lift station was engineered to move wastewater created during painting and maintenance work.

Unlike standard sanitary wastewater, paint wastewater can contain chemicals, cleaning agents, paint residue, solvents, and solids up to 2 inches in size. These characteristics require a more robust pumping and containment solution capable of meeting strict environmental and operational requirements.

To meet the engineer’s requirements and protect the environment, Romtec Utilities supplied a fully engineered prefabricated lift station solution featuring double-wall fiberglass wet well construction, double-wall PVC piping, and integrated leak detection throughout the system. Because the project followed an accelerated schedule, prefabrication and coordinated delivery were critical to minimizing on-site construction time and maintaining project timelines.

This paint wastewater lift station in Wisconsin was designed to meet local and state environmental standards while supporting ongoing airport operations. Wisconsin is known for its strong focus on water protection due to its many lakes, rivers, and groundwater resources.

Installing a wastewater lift station to process water full of paint at an aircraft facility brings unique challenges. Aircraft hangars are busy environments with strict safety and operational rules. Construction work must be planned carefully to avoid disrupting daily operations.

Wastewater generated from aircraft painting and washdown operations may contain paint residue, solvents, and contaminated wash water. These materials require proper handling to prevent damage to the environment and comply with regulations. The lift station needed to safely collect and move this wastewater away from the hangar for proper treatment.
In addition, aircraft manufacturing sites often require systems that can handle heavy vehicle traffic and allow for easy maintenance without interrupting operations. These factors shaped the design and layout of the lift station.

Romtec Utilities served as a single-source provider for this paint wastewater lift station, supporting the project from initial design through fabrication and delivery. The scope included all structural, mechanical, electrical, and control and communication components.

By prefabricating the lift station in a controlled manufacturing environment, Romtec Utilities reduced installation time, improved quality control, and minimized field labor requirements. This approach provided a significant advantage for the project’s accelerated construction schedule.

The lift station includes a prefabricated fiberglass wet well with double-wall construction and integrated leak detection. This configuration provides enhanced protection against chemical exposure and adds an additional safeguard against groundwater contamination. Factory-installed pipe penetrations and boots help maintain watertight integrity.

All internal wastewater piping was specified as double-wall PVC, complete with leak detection monitoring. This approach aligns with industrial containment requirements and provides early warning in the event of a breach in the primary pipe wall.

Romtec Utilities supplied a dedicated leak detection panel housed in a NEMA 4x stainless steel enclosure. The panel includes audible and visual alarms for local notification and is designed to monitor multiple leak detection zones, with capacity for future expansion if required.

The duplex lift station configuration incorporated submersible wastewater pumps designed to handle industrial influent with solids up to 2 inches.

Alternating pump operation helps balance wear and extend equipment life while maintaining reliable wastewater conveyance.

To accommodate service vehicle loading and site access requirements, the lift station includes a traffic-rated concrete top slab with durable access hatches. This design supports safe operation and maintenance in an active industrial setting.

Wastewater from aircraft paint hangar operations introduces a combination of operational, structural, and regulatory challenges. The lift station needed to reliably handle industrial wastewater containing chemical residues, detergents, and large solids while minimizing the risk of leaks or environmental impact.

Key challenges included:

• Industrial wastewater characteristics, including chemical exposure and solids up to 2 inches.
• Strict containment and leak detection requirements specified by the engineer.
• Durability expectations for long-term operation in a demanding industrial environment.
• Accelerated schedule, requiring a solution that minimizes on-site construction time.
• Designing a system capable of operating safely within an active airport facility.

These requirements demanded a robust integrated system designed and fabricated as a single package rather than a traditionally field-assembled lift station.

Romtec Utilities delivered a site-specific packaged paint industry wastewater lift station engineered to meet Brown & Caldwell’s requirements while supporting fast installation and long-term reliability. The system was configured as a duplex lift station, providing redundancy and alternating pump operation to ensure consistent performance.

The duplex pump setup provides backup and ensures continuous operation. The double-wall design and leak detection features help protect the environment and meet regulatory standards.

By combining engineered components into a single prefabricated package, Romtec Utilities helped streamline installation and reduce field coordination challenges for the project team.

The completed lift station for water contaminated with paint in Wisconsin provides a durable, compliant wastewater conveyance solution tailored to the demands of aircraft paint hangar operations. It safely moves wastewater while minimizing environmental risks.

The system meets all specified requirements for double-wall containment and leak detection, helping protect surrounding infrastructure and environmental resources.

Romtec Utilities is a national leader in engineered prefabricated pumping systems, specializing in wastewater, industrial, and stormwater applications. With decades of experience delivering custom packaged lift stations, Romtec Utilities partners with engineers and owners to solve complex pumping challenges efficiently and reliably.