Project Name: Luggage point STP PST Augmentation
Location: Southeast Queensland
Contract value: $2,000,000
Duration: 12 months
Project Overview
BDR Stainless was engaged by undertake critical mechanical works on the Primary Sedimentation Tank (PST) system at a major waste water treatment plant in South East Queensland. The PSTs serve as a key component in the wastewater treatment process, removing settleable solids prior to secondary treatment.
This upgrade focused on the replacement of the existing scraper bridge system with a new high-capacity scraper system—the largest of its kind. The works aimed to enhance the efficiency and reliability of sludge removal from the PSTs, supporting long-term plant performance.
Scope of Work
BDR Stainless delivered a complete turnkey mechanical solution, including:
- Development of a detailed construction methodology, tailored to the constraints of working within a live operational treatment plant.
- Design and implementation of an unconventional isolation strategy, enabling safe separation of the second-stage bioreactors from the PSTs—without process interruption and while the system remained live.
- Demolition and removal of the existing scraper bridge system, including mechanical disconnection, structural disassembly, and compliant waste handling.
- Installation of the new scraper system, involving precision mechanical alignment, drive system integration, and compatibility with existing PST infrastructure.
- Mechanical commissioning and functional testing, validating operational readiness and ensuring compliance with Urban Utilities’ stringent performance and safety standards.
Challenges & Solutions
The project presented several significant technical and logistical challenges, including:
- Demolition in a confined, wet environment, requiring elevated safety planning, sequencing, and risk controls.
- Installation of a large, custom-fabricated scraper system, with tight tolerances and the need for precise mechanical fitting to legacy tank structures.
- Missing components from the original supply, which were identified mid-installation and replaced through rapid local manufacture to exact supplier specifications, avoiding project delays.
- Continuous live plant operations, which demanded zero disruption to critical wastewater processing throughout the works.
BDR Stainless met these challenges with a solutions-driven, collaborative approach—leveraging expert in-house project management, experienced field personnel, and close coordination with Fulton Hogan and Urban Utilities. The outcome was a safe, seamless delivery in a complex, high-risk environment.
Outcome
The PST scraper upgrade was completed safely, on time, and within budget, with no impact to ongoing operations. The installation has significantly improved sludge handling reliability and positioned the facility for future performance demands.
This project showcases BDR Stainless’ capability to deliver complex mechanical upgrades within live utility environments, demonstrating precision engineering, responsive problem-solving, and a commitment to excellence.
