Modernizing plumbing systems for historic cruise terminals requires more than just technical skill — it takes careful planning, and creative problem-solving.
Originally constructed in 1927, Terminal 25 is a two-story building currently operated by Galveston Wharfs. With ongoing activity at the terminal, renovation work had to be carefully phased to avoid disruption to daily operations. Kilgore was brought in to update aging plumbing infrastructure and integrate new systems to support the terminal’s expanded structure.
Phase I – U.S. Customs and Border Protection Center
During Phase I, Kilgore’s team faced unique challenges in upgrading the plumbing infrastructure of the historic cruise terminal, where old sewer lines and outdated materials required safe, compliant solutions.
The work area included the Customs and Border Protection (CBP) area, which houses law enforcement offices, holding cells, mechanical rooms, locker room, staff restrooms, dog kennel space and secure storage rooms.
In renovation projects like this one, certain existing structures and their preliminary conditions are often unknown—especially during the discovery phase. In many cases, existing systems may be out of code, structurally weak, or pose hazards due to age. When this happens, the contractor must return to the drawing board and develop cost-effective solutions that resolve the issue without compromising efficiency or structural integrity.
During the initial inspection, the team discovered a major obstacle: integrating the new sanitary sewer system with the existing infrastructure posed a risk of failure. The existing sewer lines were only 9 inches below ground and had insufficient slope, making them incompatible with the new system.
Kilgore’s plumbing team went back to the drawing board and developed a revised design. The new plan called for excavating to a depth of 4 feet and introducing a gradual slope to allow proper flow and tie-in with the updated system. At a depth of 10 feet, the team installed a sewer ejector pump, which enabled reliable movement of wastewater from the lower-level facilities to the main sewer line.
What is a Sewer Ejector Pump?
A sewer ejector pump is essential in situations where gravity alone cannot move wastewater due to insufficient slope in the plumbing system. The system consists of a sealed collection basin, which collects wastewater from toilets and drains. As wastewater accumulates, a float switch triggers the pump to activate. A grinder pump then pushes the waste upward through a discharge pipe to reach a main. To ensure safety and efficiency, a check valve prevents backflow from returning into the basin once the pump shuts off.
This well-designed solution restored safe and efficient operations for the CBP center — seamlessly integrating new plumbing systems with existing structures while preserving the historic character of the terminal.
Interesting Find Beneath the Surface
While excavating the site, the construction crew uncovered a 100-year-old concrete slab—an example of early construction practices commonly found in coastal areas or regions with unstable, sandy soils.
Given that the cruise terminal dates back to the 1920s, it reflects the materials and techniques of the time, which often relied on locally sourced resources. In this case, the slab was made using a mix of oyster shells and coarse sand, a method once used for its natural availability and effective drainage properties.
Finding a 100-year-old concrete slab shows why revitalizing old plumbing systems in cruise terminals is so complex — crews must adapt modern solutions to work around outdated materials.
Once excavation was complete, the crew added a new layer of bank sand to stabilize the subgrade and prepare the area for underground utilities. With the foundation secured, the plumbing crew installed approximately 2,000 feet of sewer and domestic water lines to serve multiple zones across the facility.
The installation began in the men’s and women’s locker rooms, where crews installed water closets, lavatories, and showers. Work then progressed to the K9 Kennel Unit, which required plumbing for a grooming station, dog wash areas, and hand sinks—each tailored to meet the specific needs of animal care.
The facility also features a laboratory dedicated to analyzing substances and materials confiscated by border patrol agents. To ensure safety and compliance, the lab was equipped with emergency eyewash stations and safety showers designed for potential exposure to toxic or hazardous materials.
Adjacent to the lab, holding cells were outfitted with heavy-duty stainless steel penal fixtures to securely accommodate detainees in accordance with correctional facility standards.
The crew conducted pressure testing to ensure the system performed efficiently and reliably. After passing all tests, a new concrete slab was poured to finalize this phase of work. With this section ready, U.S. Customs and Border Protection (CBP) was able to move into the new space, clearing path for Phase II of the project.
Phase II – New Construction
Phase II focused on remodeling existing areas of the building. The new design expanded the original ramp system to handle increased traffic and improve accessibility, helping support the flow of passengers to larger ships. To accommodate the ramp expansion, the new design also included additional roof drains to manage stormwater runoff effectively and protect the new structure from water damage.
The phase also included extensive restrooms renovations including upgrades to water closets, urinals, and lavatories. New restrooms were also built for wharf personnel and the baggage laydown area.
As part of this upgrade, elevators were incorporated into the plan, which required installing a sump pump system to manage groundwater and prevent flooding in the elevator pits.
What is a Sump Pump?
A sump pump is a device used to remove excess water that collects in low-lying areas, such as pits or basins. When water levels rise, the pump automatically activates to discharge water away from the building, protecting structural components and preventing water damage.
Kilgore’s plumbing team approached each stage of the project with care and expertise. From uncovering century-old construction elements to integrating modern plumbing systems, they adapted to unexpected challenges like shallow, outdated sewer lines and unstable soil conditions.
The new enhancements ensure that Terminal 25 can meet the growing demands of today’s cruise industry, including increased passenger volumes, enhanced security operations, and improved support for passengers and wharf personnel. With a fully updated infrastructure now in place, the Galveston Wharfs’ historic cruise terminal is well-positioned to continue welcoming travelers from around the world — honoring its past while embracing a future of continued growth and revitalization.
With careful engineering and a phased approach, Kilgore’s plumbing upgrades preserved the integrity of this historic cruise terminal, preserving its structural integrity while supporting the future of the terminals operation.
