Innovative Water Treatment Works at Bishops Green
Location: Bishops Green, South of England
Delivered: 4-6 weeks
Project Value: £32,252.00
At the core of manufacturing and engineering lies the drive to solve complex problems with innovative solutions. This ethos was brought to life at Bishops Green Water Treatment Works, where a tier 1 construction company partnered with our team at Steelway to revitalise and modernise a critical Water Treatment facility. With a total project value of £32,252.00, this collaborative effort showcases the power of bespoke engineering in the water treatment sector.
Challenges Faced
The Bishops Green WTW, a vital hub in the South of England’s water network, was facing multiple operational challenges with ageing borehole flooring reaching the end of its lifecycle, new filtration systems required secure pipe supports and an urgent need for a safe maintenance platform to access the state-of-the-art Amazon filters.
The solutions needed to integrate seamlessly with the existing infrastructure, enhance safety and comply with strict industry regulations, all while ensuring minimal disruption to ongoing operations.
Our Engineering team at Steelway embraced the challenge with a meticulous and innovative approach. Each aspect of the project was carefully planned and executed to deliver a long-lasting impact.
Flooring Replacement:
The deteriorated borehole flooring posed both a safety hazard and a maintenance issue. The solution? Durable open mesh industrial flooring, fabricated and installed to withstand the site’s demanding conditions. The new flooring not only resolved the safety concerns but also ensured a robust foundation for future operations.
Precision Pipe Supports:
With the addition of new filtration systems came the need for secure pipework alignment. Bespoke steel pipe supports were engineered and installed, providing unmatched stability and ensuring operational reliability. These supports were designed with precision to accommodate the intricate layout of the plant’s existing infrastructure.
Custom Maintenance Platform:
The highlight of the project was the design and installation of a custom maintenance platform. The platform’s purpose was two fold: to ensure safe access for operators and to facilitate efficient maintenance of the Amazon filters. The design process was iterative and responsive to the site’s unique challenges.
- Initial Design Adjustments: A comprehensive site survey revealed the need to adjust the platform’s height, ensuring handrails did not obstruct the operation of the filters’ swing lids.
- Staircase Redesign: A rising pipe restricted the placement of the staircase, prompting a redesign that included a wraparound platform and an external staircase for optimal access.
- Handrail Innovation: Internal handrails were deemed impractical, so a fully compliant perimeter handrail system was developed to guarantee operator safety without impeding functionality.
"From designing durable open mesh flooring to secure pipe supports, every element was tailored to enhance safety, reliability and long-term performance. The custom maintenance platform was particularly rewarding to develop, requiring iterative adjustments to fit the site’s constraints while ensuring operator safety and accessibility. It’s always exciting to see thoughtful design elements and engineering come together to solve real-world challenges." – Darren Thompson, Lead Engineer
Throughout the project, the team demonstrated an unwavering commitment to problem-solving. For example, when proposed vertical ladders were rejected for safety reasons, the platform height was increased and a staircase was incorporated instead. This adaptability ensured the final design met both the client’s operational needs and regulatory standards.
Bespoke flooring panels and a wrap around platform supported by beams between filters and pipework ultimately provided a secure and ergonomic solution. These components were fabricated with precision, reflecting the highest standards of engineering excellence.
Delivering Results
The completion of the Bishops Green project marked a significant milestone in the collaboration between Falco Construction Ltd and our engineering team. Key outcomes included:
- Safety: The new flooring and maintenance platform created a safer environment for site personnel, reducing risks during maintenance activities.
- Efficiency: Secure pipe supports and improved access to the filtration system streamlined daily operations and maintenance.
- Compliance: The entire project adhered to industry safety standards, ensuring long-term operational reliability.
The Bishops Green WTW project exemplifies how bespoke engineering can solve complex challenges in critical infrastructure. By combining innovative design, precision manufacturing and seamless integration, the project delivered enhanced functionality and safety, reinforcing the importance of tailored solutions in the manufacturing and engineering sectors.
This success story stands as a testament to the ingenuity and dedication of the Steelway team, proving once again that with the right expertise, any challenge can be met with a solution that exceeds expectations.
From surveying to installation, our team has been hands-on every step of the way, ensuring that every detail aligns with the strict water industry standards.
To learn more about our products and services and how we can help improve yourprojects, call 01902 451733 or sales@steelway.co.uk
