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Brock Solutions is an engineering solutions and professional services company specializing in the design, build and implementation of real-time solutions for broad based industrial/manufacturing and transportation/logistics organizations globally.
The Region of Waterloo is a mid-sized community located in the heart of southwestern Ontario's greenbelt. With a population of more than 630,000 people, The Region of Waterloo is one of the fastest-growing areas in Ontario.
- Existing SCADA system and PLCs across over 157 facilities needed to be modernized while maintaining uninterrupted water service
- Had to balance large-scale system upgrades with critical nature of water supply
- Minimized downtime and enhanced operational efficiency
- Increased resilience, reduced compliance risks, enhanced service reliability
- Successful five-year transformation, now in its final phase
Challenge
Modernizing Critical Water Systems Without Disruption
The Region of Waterloo, a regional municipality in southwestern Ontario, provides drinking water and wastewater treatment to over 600,000 residents across three cities and rural municipalities. To maintain high-quality service and comply with evolving industry standards, The Region of Waterloo sought to modernize its SCADA system and PLC infrastructure.
While the existing system functioned, it lacked the advanced capabilities necessary for long-term efficiency, security, and resilience. The scope of the project was significant—157 facilities across a large geography and of varying sizes and complexity needed to be upgraded. However, modernizing critical water infrastructure posed a unique challenge: these systems could not be taken offline without disrupting essential services.
The Region of Waterloo required an integration partner that could navigate the technical and operational complexities while achieving continuous water availability. They sought a turnkey solution provider capable of both system integration and panel supply. Brock Solutions was selected as their partner, marking the beginning of a highly collaborative, multi-year transformation.
Solution
Phased, Collaborative Approach to Water System Upgrades
Brock Solutions leveraged its expertise in water and wastewater systems to create a tailored, phased approach to modernization. Using Rockwell Automation technology, they developed standardized solutions for different facility types, delivering consistency across the entire network.
For smaller outdoor facilities, CompactLogix® controllers with onboard I/O provided a streamlined and maintainable solution. Medium-sized sites used newer CompactLogix® models, while the most complex facilities required ControlLogix® controllers with full redundancy for reliability. Stratix® switches, distributed I/O, and digital ring topology provided robust communication between systems. These standardized solutions enabled operators to work more efficiently across different sites, reducing downtime and improving issue resolution.
A key factor in the project’s success was continued stakeholder engagement. “Communication has been a key factor in the success of this project,” says Michael Rowinski, Senior Manager and Technical Lead, Brock Solutions.
From the outset, Brock Solutions involved operators, technicians, and management in every phase of implementation. Weekly meetings, workshops, and hands-on testing sessions helped everyone—from seasoned operators with decades of IT experience to IT specialists securing the network—have a voice in shaping the solution.
To mitigate risks during facility transitions, Brock Solutions employed advanced testing strategies, including digital twin simulations. SCADA screens and PLC programs were built and tested in a controlled environment before deployment. Factory Acceptance Tests (FATs) allowed operators to interact with the system in real-world scenarios, identifying potential issues before they impacted live operations. During critical cutovers, temporary systems were deployed to maintain uninterrupted water service while new panels and PLCs were installed.
Result
Standardized, Resilient, and Future-Ready Water Systems
Now in its final phase, the five-year project has transformed The Region of Waterloo’s operations. By standardizing automation solutions across all facilities, operators can now diagnose and resolve issues more quickly, leading to reduced downtime and increased system resilience. Enhanced monitoring capabilities provide better insights into water usage, system pressures, and response times to main breaks and emergencies.
Additionally, improved network security safeguards critical infrastructure from potential cyber threats. Brock Solutions played a key role in bridging the IT/OT gap, helping to develop an OT cybersecurity framework tailored to The Region of Waterloo’s needs.
Beyond the technical improvements, the project’s success is rooted in strong collaboration and trust. “If I could emphasize one thing, it’s how much work went into building the relationship between Brock Solutions and The Region of Waterloo and getting buy-in from every person,” says Andrew Calder, Senior Project Engineer, The Region of Waterloo.
By fostering a culture of open communication and continuous learning, both Brock Solutions and The Region of Waterloo conveyed that modernization was not just about upgrading technology, but also about empowering people. Thoughtful change management, extensive training, and a shared commitment to problem solving have positioned the region for long-term success.
With the last major facility now nearing completion, The Region of Waterloo has achieved a modernized, future-ready water management system—one that will serve its customers reliably for decades to come.
Published June 23, 2025