Building Resilience: Rehabilitation of the Caguas Norte Water Filtration Plant

In the heart of Caguas, Puerto Rico, lies one of the region’s most critical infrastructures, the Caguas Norte Water Filtration Plant. Serving over 46,000 residents across Caguas and Gurabo, this facility is a cornerstone of public health and quality of life. Yet, by early 2023, decades of wear and outdated systems meant the plant was struggling to meet modern operational and regulatory demands.

A Call for Modernization

The project began in March 2023, commissioned by the Puerto Rico Aqueduct and Sewer Authority (PRASA) with a clear mission: repair, improve, modernize, and replace aging systems throughout the facility. From raw water intake units to sludge treatment systems and power infrastructure, every corner of the plant required upgrades to meet industry standards, ensure compliance, and increase treatment capacity to reduce the municipality’s reliance on external water sources.

Early Challenges and Key Decisions

The first hurdle was not about engineering—it was about access. The proposed site was cluttered with abandoned cars, which had to be removed before surveys and design work could even begin. Space constraints also shaped the project, as engineers were challenged to reduce the plant’s footprint while improving capacity. This led to a compact, package-plant-inspired layout, lowering construction costs, simplifying maintenance, and boosting long-term operational efficiency.

Another turning point came when the client requested pre-sedimentation heli-cones to tackle turbidity issues. Initially considering a second-hand unit from another facility, the team pivoted after expert consultation recommended a new system. This decision led to additional pump upgrades and electrical improvements, ensuring reliable performance for decades to come.

Engineering a Modern Solution

The design, completed in August 2024, includes a conventional municipal water treatment plant with:

• Aeration systems to improve water quality. • Pre-sedimentation heli-cones to manage turbidity and reduce chemical consumption. • Coagulation, flocculation, sedimentation, filtration, and disinfection units for comprehensive treatment. • New sludge treatment systems with holding tanks, thickeners, and dewatering boxes. • Above-ground filter galleries for accessibility and ease of maintenance. • Recirculation systems to improve water efficiency and sustainability.

Notably, the inclusion of heli-cones marked a technological leap, addressing high turbidity events after storms and protecting downstream treatment units while reducing chemical use.

A Lasting Impact

Once completed, the rehabilitated Caguas Norte WTP will serve 46,530 residents across multiple communities, minimizing operational shutdowns and ensuring reliable potable water supply even during adverse conditions. The client praised the project’s innovative layout, increased capacity, and improved operational efficiency, positioning the Caguas Norte WTP as a benchmark for future water infrastructure projects on the island.