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Mebane outlines $90 million wastewater expansion to support growth and Buckhorn development
Summary
City officials told a March 19 joint meeting that Mebane will expand its wastewater treatment capacity from 2.5 mgd to 4.0 mgd (with future expansion to 6.0 mgd), a roughly $90 million project expected online in late 2027–2028; pump station constraints and proposed gravity‑line work were discussed as prerequisites to opening additional acreage for development.
MEBANE / HILLSBOROUGH, N.C. — City of Mebane officials on March 19 described a planned wastewater treatment expansion and related pump‑station work they say are needed to support housing and industrial development around the Buckhorn Economic Development District.
John Dodson, Mebane’s Water Resources Director, said the city currently treats up to 2.5 million gallons per day (mgd) and operates about 6,400 service connections and 21 pump stations. Dodson said the planned treatment‑plant expansion will increase capacity to 4.0 mgd, with design provisions allowing later expansion to 6.0 mgd; construction is expected to be complete in 2027–2028 at an estimated cost of about $90 million.
Kyle Smith, Mebane’s Public Utilities Director, reviewed constraints at four primary pump stations. He said the GE Pump Station has an operational capacity of about 173,000 gallons per day with only roughly 34,000 gpd of remaining available capacity; Graveley Hill has about 115,000 gpd operational capacity with roughly 35,000 gpd available. Smith proposed extending a 12‑inch gravity line under I‑40/85 to Graveley Hill—an estimated $2 million project—saying it could free roughly 500 acres north of the interstate for industrial or warehouse uses.
City and county officials tied wastewater capacity to housing approvals. Preston Mitchell, Mebane assistant city manager, said the city’s wastewater capacity policy limits certificates of occupancy to roughly 400–450 homes per year to manage debt service and avoid "paper flow" counting of permitted developments not yet under construction. Mayor Ed Hooks said the city could allow more connections once the new plant is online, using the phrase that the city could "open a barn door" to more certificates of occupancy after expansion.
Several projects identified by staff seek federal funding for pump upgrades and force‑main work; however, officials said funding sources for the gravity‑line extension were not yet identified. Dodson and Smith offered to provide more detailed, technical flow data to county contacts following the meeting.
Why it matters: wastewater treatment and pump‑station capacity determine how much new residential and industrial development can be supported without unplanned system strain. Upgrades described at the meeting are also tied to state water‑quality requirements for Jordan Lake.
Next steps: the city expects to complete the plant expansion project in the 2027–2028 timeframe and pursue federal funding for station upgrades; staff will share detailed flow studies and continue coordination with Orange County and developers.
