Residuals Conveyance System – Segment 2
Louisville, KY / Prospect, KY
Estimated Completion in 2026
The Crescent Hill Water Treatment Plant (CHWTP) Residuals Conveyance System – Segment 2 project involved installation of dual 24-inch diameter pipelines connecting Zorn Avenue and River Road to Louisville Water’s B.E. Payne facility in Prospect, Kentucky.
The project enhanced long-term system reliability while providing additional operational redundancy within Louisville Water’s treatment network.
Impact & Purpose
The completed conveyance segment supports efficient residual transport and overall system resiliency.
- Major water infrastructure upgrade supporting Louisville Water operations
- Improved reliability and redundancy within the residuals conveyance system
- Reduced environmental impact through approximately 4,700 LF of trenchless installation at critical creek crossings
- Strengthened long-term treatment system performance
Project Scope
- Installation of dual 24-inch diameter pipelines over approximately 72,000 linear feet,, including 67,300 LF of open-cut construction
- Connection between Zorn Avenue/River Road and B.E. Payne facility
- Construction performed along approximately 6 miles of active roadway corridor
- Site restoration and environmental compliance measures
Technical Complexity
Construction required precise execution across environmentally sensitive areas and developed corridors. The project demonstrates MAC Construction’s capability in large-diameter pipeline installation and trenchless infrastructure delivery.
Key complexities included:
- Dual horizontal directional drilling (HDD) operations to minimize environmental disturbance at creek crossings
- Installation of large-diameter pipeline over extended linear distance
- Coordination within active roadway and utility corridors
- Sequenced construction to maintain system integrity and regulatory compliance
- Construction within close proximity to the Ohio River, requiring flood risk planning and mitigation
- Phased construction and traffic control along River Road to maintain continuous public access
- Continuous stakeholder coordination and communication to maintain access for residents, businesses, park facilities, emergency services, and local events
