What happens when a community’s wastewater needs outgrow its infrastructure? You build something bigger, better, and smarter.
That’s precisely what we’re doing in Saluda, South Carolina. This $5 million project is the largest in IPCO’s history, and it’s all about stepping up to meet a growing demand while creating new standards for efficiency and sustainability.
It’s big and bold, reminding us why teamwork and innovation are critical. Here’s an overview of this remarkable project for those who aren’t wastewater connoisseurs.
Breaking Down the Process (Literally):
Wastewater doesn’t magically disappear after leaving your sink, tub, or toilet. It goes through a complex process to make it clean and safe again. That’s where this state-of-the-art treatment plant comes in. While we’re not handling the dirty water, IPCO is responsible for the electrical systems that make this system work. Let’s walk through the process:
Step 1: Headworks
This is where the magic starts—or, really, where the trash is raked out of the water. Headworks act like the plant’s bouncer, removing everything that doesn’t belong, such as large debris, grit, and other random things people flush down the toilet. Our job at IPCO is installing the electrical systems that keep those rakes and filters pumping.
Step 2: ICEAS (Intermittent Cycle Extended Aeration System)
The water then moves to the ICEAS basins. ICEAS stands for Intermittent Cycle Extended Aeration System and is where the sludge processing begins. It’s essentially a smart cleaning process that happens inside one tank. These tanks handle aeration, settling, and decanting all in one place, which makes them incredibly efficient. They’re powered by Variable Frequency Drives (VFDs), the technology that ensures proper airflow and oxygen levels. Our role here is huge.
IPCO installs all the conduits and wiring to connect these systems to their controls. This is the epitome of efficiency meeting innovation. This large plant will have two operational tanks, each slightly larger than a football field and each holding about two million gallons of water.
Step 3: Filtration & UV Channels
After the water leaves the ICEAS basins, it moves through filtration to catch any remaining particles. Then, it’s off to the UV channel for a final clean-up, where ultraviolet light kills any lingering bacteria. IPCO’s role in this part of the project is to ensure the systems controlling the filtration systems have reliable electrical power and function properly.
Duct Locks: Reimagining the Wheel
In this project, our team implemented a solution we have been innovating and prototyping at IPCO. A significant pain point in this industry is finding quality spacers to hold the conduit in place until concrete has been poured. Currently, the market has a version of these that tend to be cheap, brittle, and unsustainable. This version also requires a significant amount of onsite labor and installation. Our team has been working on custom-designed duct locks, which had to be engineered and approved by the general contractor for this project. These custom-designed spacers are durable and unlike anything currently on the market.
And we didn’t stop there. Our team pre-assembled 20-foot duct banks off-site, cutting labor time in half and keeping us from overusing the expensive glue needed to assemble the duct locks on-site. This is the kind of innovation that sets us apart at IPCO. We have created a product that saves time and money and is setting a new industry standard for future projects like this.
Why This Project Matters
This project is a game-changer for the town of Saluda. Currently, the area’s wastewater is shipped over 30 miles away for treatment. When this plant is up and running, millions of gallons of water will be processed daily in the community. That’s incredibly important for Saluda’s efficiency, environmental impact, and future growth—Phase I involves adding to the current plant. We should finish sometime this summer. Phase II will focus on overhauling the existing plant to make it more efficient.
The Big Picture
This project shows that IPCO doesn’t shy away from complicated jobs or challenges. Our team is all in, from installing conduits for cutting-edge systems to revamping and improving duct locks to streamline the process. While there’s still a lot of work to do before the plant is completed in 2026, we’re excited to play such an essential role in one of our communities.
Here’s to the complex, necessary, and rewarding work of improving our communities.
