GBRA Stein Falls Water Reclamation Facility Expansion

The project also introduced a new administration building to support the facility’s growing operational needs and accommodate future population growth in the New Braunfels region. Given the facility’s continuous exposure to hydrogen sulfide (H₂S) and harsh microbial conditions typical of wastewater environments, the design team required a durable waterproofing and corrosion-resistant system to protect critical concrete infrastructure. Specifications called for either a UV and chemical-resistant lining or an integral crystalline admixture, ensuring long-term structural integrity and reduced maintenance across high-exposure zones.

To meet these performance objectives, Xypex Bio- San was selected for use in approximately 1,585 yd³ of concrete across key process structures, including the coarse screening and grit removal units, clarifier, RAS-WAS system, tertiary filters, effluent flow meter, sludge storage basin, chemical system, and lift station. Bio-San’s unique crystalline formulation integrates antimicrobial technology that resists microbial-induced corrosion (MIC) while providing integral waterproofing protection. In addition, over 32,900 ft² of interior surfaces received Xypex Concentrate to ensure complete crystalline coverage and long-term watertight performance. The Xypex crystalline system delivered a permanent, self-healing waterproofing solution, eliminating the need for external membranes and reducing the project’s lifecycle maintenance costs. Its proven resistance to chemical attack and hydrostatic pressure supports GBRA’s long-term goal of maintaining a sustainable, high-performance wastewater facility designed to protect both infrastructure and the environment.