Rapid Response: Precast Helps Restore Wastewater Service After Hurricane Helene
When Hurricane Helene damaged a critical sewer pump station in Lake Lure, North Carolina, untreated wastewater began flowing into the lake, threatening water quality and the surrounding ecosystem. With two communities depending on the station, restoring service became an urgent priority. Gainey's manufactured custom precast concrete structures at its Louisiana plant, more than 700 miles from the project site. Completed and delivered on an accelerated schedule, the structures helped restore wastewater service and stop the discharge of untreated sewage into the lake.
Fast Facts
- Project Name:
- Lake Lure Pump Station Restoration
- Location:
- Lake Lure, North Carolina
- Precast Products Used:
- Custom precast concrete wet well vault, Precast concrete pressure-reducing valve structure, Precast concrete utility vault
- Precast Producer:
- Gainey's
- Completion Date:
- November 28, 2024
The Challenge
Hurricane Helene severely damaged a sewer pump station serving two communities in Lake Lure in September 2024. The damaged infrastructure was releasing thousands of gallons of untreated wastewater into the lake, creating an environmental emergency that required immediate action.
Replacing the station presented significant engineering and logistical challenges. The new structures needed to match the dimensions and utility connections of the existing system while accommodating custom pump requirements and specialized equipment.
The project also faced an extremely compressed schedule and multiple design revisions. The team needed to develop, produce and deliver a permanent replacement while recovery efforts continued.
Precast Solution
Gainey’s worked with contractor Morgan Corp. and engineer LaBella Associates to design and manufacture three custom precast concrete structures for the damaged wastewater system.
The replacement structures included:
- Wet well vault: 7 feet, 10 inches by 10 feet inside dimensions, with a depth of 5 feet, 6 inches.
- Pressure-reducing valve structure: 5 feet by 8 feet inside dimensions, with a depth of 5 feet.
- Utility vault: 7 feet by 11 feet inside dimensions, with a depth of 6 feet, 1 inch.
Each structure was designed to integrate with the existing infrastructure, minimizing the need for field modifications.
Gainey’s design, estimating, operations and production teams coordinated revisions, secured specialized materials and accelerated manufacturing. Beginning with initial project discussions on Oct. 2, 2024, the team completed production within approximately two weeks.
The finished structures were transported from Louisiana to North Carolina and delivered ahead of schedule, allowing installation work to proceed without delays.
- 3 Custom precast concrete structures manufactured for the replacement system
- 700+ miles Distance from the manufacturing plant to the project site
- 2 weeks Time from initial project discussions to completed production
- $53,289 Total reported project cost
- $34,089 Cost of precast concrete
Why Precast?
Precast concrete provided the speed, precision and durability required to replace critical wastewater infrastructure under emergency conditions.
Manufacturing the structures in a controlled plant environment allowed production to proceed while site preparation and disaster recovery activities continued. Unlike cast-in-place construction, which would have required on-site forming and curing, precast manufacturing reduced the amount of construction work needed at the damaged location.
Precast also allowed the team to customize each structure to match existing dimensions and utility connections. This precision reduced the need for field adjustments and helped simplify installation despite the accelerated schedule.
The material’s strength and resistance to demanding wastewater environments provided a durable, long-term replacement rather than a temporary repair. These advantages made it possible to deliver permanent infrastructure quickly while addressing the project’s structural and operational requirements.
Results
The Lake Lure Pump Station Restoration project was completed Nov. 28, 2024, restoring essential wastewater infrastructure for two communities affected by Hurricane Helene.
Restoring the pump station stopped the discharge of untreated sewage into Lake Lure, helping protect the lake’s water quality and surrounding ecosystem.
The precast structures arrived ahead of schedule, allowing the contractor to maintain progress during the emergency response.
Beyond the immediate recovery effort, the replacement structures provide permanent wastewater infrastructure designed for long-term service. The project demonstrates how off-site precast manufacturing, customized engineering and coordinated delivery can help communities restore critical infrastructure following a natural disaster.
- Written by:
- Heather Bremer, NPCA Director of Communications
- Source:
- Lake Lure Pump Station Restoration, Built for Purpose Awards submission
- Published:
- October 22, 2026
- Last Update:
- October 21, 2026
Testimonial
"Y’all worked with us closely to find the quickest solutions for the emergency project and, as it turned out, you had the precast on site even a couple days ahead of when the contractor was ready to use it (i.e. absolutely perfect timing)!"
PE, LEED AP, DBIA LaBella Associates