When an aging auger screw at the Morrilton Wastewater Treatment Plant in Arkansas began to fail, it created a costly and complex challenge. Years of wear had caused the auger’s bottom bearing to break loose, dropping the screw into the concrete trough below. The resulting damage allowed water to leak beneath the auger, cutting system performance by more than half and threatening to derail daily operations.
The plant’s auger, designed to transport raw sewage from the lower basin up to the lagoon system, had been operating at roughly 2,500 gallons per minute—a far cry from its intended 6,000 GPM capacity. The broken bearing had allowed years of abrasion to erode the concrete beneath, creating large voids where water escaped instead of being pumped forward.
“With those voids under the auger, a lot of the water they were trying to move just leaked right back down,” said Asa Baker, Regional Director, Midwest Infrastructure Coatings. “It wasn’t doing its job efficiently at all.”
Rather than replacing the entire auger assembly—a project that would have cost the city over $1 million—Midwest Infrastructure Coatings used OBIC 1200C and 1306 closed-cell polyurethane foam products to rebuild the damaged trough and seal the structure. The project covered approximately 600 square feet and was completed in just five working days by a three-person crew of Cole Nordin, Nate Deaton, and Nick Townley.
Once cured, the OBIC products restored structural integrity and eliminated water loss beneath the auger. “With the wet season approaching, restoring the system’s full efficiency was critical to prevent backups and overflow risks. After we were done, the flow rate went back up to about 5,000 gallons per minute,” he said. “That’s almost full capacity again—and we saved the city a tremendous amount of money.”
This project marked a first-of-its-kind use of OBIC coatings on an auger screw trough. “To my knowledge, no one had used this system for that type of structure before,” said Baker. “It was exciting to figure it out and see it work so well.” The successful outcome not only demonstrated the adaptability of OBIC products but also showcased the value of creative problem-solving within the installer network.
From start to finish, the project highlighted the benefits of OBIC’s quick-curing, high-performance linings, engineered to bond tightly to concrete, resist corrosion, and extend the life of wastewater infrastructure. The restored trough now functions as if brand new, with minimal downtime and a fraction of replacement cost.
If you’re looking for a fast, durable, and cost-effective alternative to traditional replacement, visit midwestinfrastructurecoatings.com, or contact OBIC to learn how our certified installers can help extend the life of your wastewater infrastructure.
