Case Study: Metro Sewer District Drainage Forebay Project

Project Overview

Lawrence & Associates Concrete Design partnered with the Louisville Metropolitan Sewer District (MSD) to construct a 100-foot drainage forebay for the agency’s Central Maintenance Facility. The project required close collaboration with architects, structural engineers, and material suppliers to meet highly specific design criteria and performance standards.

Because of the forebay’s unique design, the project demanded precision, communication, and problem-solving at every stage — from material selection and site preparation to pour sequencing and finish quality.

Challenges

• Unusual Design Requirements: The forebay’s design specifications were highly customized and required exact adherence to engineered plans.
  
  
• Material Constraints: The concrete mix needed to meet strict structural and performance requirements while remaining workable for field application.
  
  
• Weather and Seasonal Conditions: Work began in December 2024, creating difficulties due to cold temperatures and winter precipitation. Flooding on-site complicated several phases of the project.
  
  
• Structural Complications: Midway through construction, unexpected structural issues were identified that required adjustments to reinforcement and placement strategy.
  
  
• Coordination Across Teams: Success required consistent collaboration between engineers, architects, and the concrete supplier, ensuring that all specifications were met without compromising safety or performance.
  

Our Approach

The success of this project stemmed from relationship-based collaboration and technical adaptability — two hallmarks of how Lawrence & Associates operates.

• Team-Oriented Execution: From day one, we fostered a cooperative working environment between our crew, the project engineers, the architect, and the Metro Sewer District team. This ensured alignment on design intent, quality control, and timelines.
  
  
• Custom Concrete Mix Development: We partnered closely with our concrete supplier to refine a mix design that satisfied the structural requirements while maintaining workability for the complex forebay geometry.
  
  
• Adaptation to Weather: Despite winter temperatures and repeated flooding events, our team stayed on schedule through careful site management, protection measures, and controlled curing practices.
  
  
• Quality Assurance: Every phase of the pour was monitored and documented to ensure compliance with MSD’s specifications and Kentucky engineering standards.
  

Results

• Successful Completion: The 100-foot drainage forebay was completed in July 2025, meeting all performance and design standards.
  
  
• Collaboration Excellence: Strong communication among all stakeholders minimized delays and maintained design integrity.
  
  
• Innovative Execution: The project demonstrated how technical challenges can be solved through relationship-driven teamwork and hands-on engineering problem-solving.
  
  
• Recognition: This project has been nominated for the Kentucky Concrete Association’s 2025 Concrete Design Awards, recognizing its excellence in design, execution, and collaboration.
  

Why This Project Matters

This project represents more than a successful concrete installation — it showcases how Lawrence & Associates approaches every complex job: through teamwork, innovation, and an unwavering commitment to quality. By working shoulder to shoulder with engineers, architects, and suppliers, we ensure that even the most intricate designs are built to last.