Project Name: Major STP Upgrade
Location: Southeast Queensland
Contract value: $12,000,000
Duration: 18 months
Scope of Work
BDR Stainless was engaged to deliver the manufacture, installation, and commissioning of above-ground mechanical systems as part of a major SEQ sewage plant upgrade.
Our scope included:
- Installation of free-issued mechanical equipment, including penstocks, valves, grit classifiers, blowers, mixers, lifting devices, and screening systems.
- Project-wide supply, manufacture, and installation of above-ground stainless steel pipework, fabricated to meet exacting specification and corrosion resistance requirements.
- Hydrostatic and pneumatic pressure testing, conducted in accordance with AS4041 and project-specific quality assurance standards.
- Design, fabrication, and installation of site-wide structural and access systems, including platforms, walkways, stairs, and supports.
Challenges & Learnings
Delivering a project of this scale during a time of the global pandemic and Southeast Queensland floods presented several significant challenges. These had wide-reaching impacts on labour availability, supply chains, and site logistics.
Key Challenges Faced:
- Labour Constraints: Travel restrictions and workforce shortages due to health regulations, NSW hard border, isolation requirements placed pressure on resourcing. Maintaining productivity while ensuring the safety and well-being of all personnel required agile workforce planning and a strong commitment to compliance.
- Global Supply Chain Disruptions: Ongoing international shipping delays and material shortages affected the timely delivery of key components. We adapted by sourcing alternate materials, engaging local suppliers where possible, and restructuring installation sequences as necessary
- Severe Weather Events: The South-East Queensland floods in early 2022 caused widespread disruption to site access and logistics. Our team acted quickly to protect in-progress works and re-sequenced works.
Adaptability & Growth
These challenges demanded flexibility, fast decision-making, and a collaborative approach across all levels of the project team. BDR Stainless successfully:
- Maintained momentum by adapting project workflows on the fly, reshuffling resources and accelerating off-site fabrication when needed.
- Strengthened internal systems for risk management, procurement, and remote coordination.
- Reinforced the value of clear communication and proactive client engagement — essential in navigating external constraints.
Despite these pressures, the project was delivered safely, to specification, and on time — a testament to the resilience, capability, and professionalism of the entire BDR Stainless team.
