USA Rare Earth, Inc. has selected Fluor Corp. and WSP Global Inc. as its engineering, procurement and construction management (EPCM) partners to advance the Definitive Feasibility Study for its Round Top rare earths project in Sierra Blanca, Texas, the company said.

The two firms will support completion of the study under an accelerated mine development plan aimed at moving the project toward commercial production. The work follows a competitive evaluation of multiple bids, according to the company.

USA Rare Earth plans to complete the feasibility study in two phases. The first phase, covering the scope typically addressed in a pre-feasibility study, will rely on results from solvent extraction pilot testing currently underway at the company’s demonstration facility in Wheat Ridge, Colorado.

Phase 2

The second phase of the study will incorporate data from extended operations at the Wheat Ridge demonstration plant, which is expected to run for at least 2,000 continuous hours, with operations currently scheduled to conclude in October 2026.

In parallel with the feasibility work, the company plans to conduct confirmatory and geotechnical drilling at the Round Top site during the first half of 2026, along with a heap leach optimization study to support mine design and engineering.

Together, the studies and field work are intended to support a final investment decision and progress toward commercial production of heavy rare earth oxides. USA Rare Earth is currently targeting late 2028 for the start of commercial production.

Round Top is being developed as a domestic source of heavy rare earth elements, including yttrium, as well as other technology metals such as hafnium, zirconium and gallium.

Fluor and WSP have experience delivering large-scale mining, processing and infrastructure projects in North America and internationally, the company said.

Alex Moyes, vice president of mining and processing at USA Rare Earth, said the partners’ experience would support the company’s efforts to advance the project toward commercial delivery.

The Round Top project is part of a broader push to expand domestic rare earth and magnet manufacturing capacity. The feasibility work comes as a new rare-earth magnet plant has recently been completed in South Carolina, adding downstream processing capacity and strengthening the U.S. rare earth supply chain.

Round Top Rare Earth Project Factsheet

Project Overview

Project Name: Round Top Rare Earth Project

Location: Sierra Blanca, Texas, USA

Owner: USA Rare Earth, Inc.

Current Phase: Definitive Feasibility Study (DFS)

Target Commercial Production: Late 2028

EPCM Partners

Fluor Corporation – Lead EPCM Partner

WSP Global Inc. – EPCM Partner

Selected through competitive bid evaluation

Global leaders in mining, processing, and large-scale infrastructure

Experience: Tens of billions of dollars in complex, multi-year projects across North America and internationally

Products

Heavy Rare Earth Oxides (HREOs)

Yttrium

Hafnium

Zirconium

Gallium

Development Strategy: Accelerated Mine Plan

DFS Phase 1:

Utilizing solvent extraction (SX) pilot work results

Conducted at Wheat Ridge, Colorado facility

Scope equivalent to Pre-Feasibility Study

Currently in progress

DFS Phase 2:

Based on demonstration plant data

Minimum 2,000 continuous operating hours

Expected completion: October 2026

Location: Wheat Ridge, Colorado

Parallel Activities (H1 2026):

Confirmatory drilling at Round Top site

Geotechnical drilling program

Heap leach optimization study

Mine design and engineering support

Key Facilities

Wheat Ridge, Colorado:

Solvent extraction pilot plant (operational)

Demonstration plant (2025-2026)

Round Top Site, Sierra Blanca, Texas:

Drilling programs (2026)

Future mine operations

Project Timeline

2025: Solvent extraction pilot work ongoing

H1 2026: Site drilling programs and heap leach study

October 2026: Demonstration plant operations complete

2026-2027: DFS completion

Late 2028: Commercial production start

Strategic Importance

Establishes domestic U.S. supply of heavy rare earth elements

Reduces dependency on foreign sources

Strengthens U.S. rare earth value chain

Supports national security and defense applications

Enables clean energy and advanced technology manufacturing