JK Fabrications Ltd

Bury Primary WwTW – PST Bridge Scraper Replacement

Bury Primary WwTW - PST Bridge Scraper Replacement

Background

JK Fabrications was contracted to undertake a major mechanical replacement programme at Bury Primary Waste Water Treatment Works (WwTW).

The project involved the decommissioning, removal, and safe disposal of four ageing Primary Settlement Tank (PST) bridge scrapers, followed by the design, manufacture, supply, installation, testing, and commissioning of four new bridge scrapers and associated mechanical components.

This upgrade formed part of a wider improvement initiative to enhance sludge settlement efficiency and long-term plant reliability.

Objectives

• Safely remove and dispose of four existing PST bridge scrapers
• Design and fabricate four new scraper mechanisms built to modern standards
• Ensure a seamless transition between decommissioning and installation
• Deliver the works with minimal impact on the live wastewater treatment process
• Provide the client with a durable, low-maintenance solution for improved operational performance

Scope of Works

• JK Fabrications delivered a complete turnkey solution covering every stage of the works:
• Decommissioning and removal of four existing PST bridge scraper assemblies and associated components
• Design and in-house fabrication of new scraper bridges, drive systems, and mechanical parts
• Supply and installation of the complete scraper systems, including scum boards, drive units, and interface components
• Testing, inspection, and commissioning of all equipment to verify full operational performance
• Full documentation and certification to support client handover and compliance requirements
• Each new bridge scraper was designed to provide improved mechanical strength, corrosion resistance, and reliability, using robust materials and coatings suitable for long-term wastewater service.

Project Challenges

The project required meticulous planning due to the live operational status of the treatment works.

All decommissioning and installation activities had to be coordinated to maintain continuous site operations while ensuring the highest safety standards.

JK Fabrications’ dedicated site team implemented detailed risk assessments and method statements, supported by our internal Health & Safety specialists.

Working within tight space constraints and weather-sensitive conditions, the team maintained strong communication with site management to achieve safe and efficient delivery.

Outcome

The project was completed on time and within budget, successfully replacing all four Primary Settlement Tank scrapers with modern, high-performance units.

Each scraper system was rigorously tested and commissioned to confirm full compliance with operational and safety standards.

The new equipment has delivered enhanced process reliability, reduced maintenance needs, and improved sludge settlement performance at Bury WwTW.

The success of this project highlights JK Fabrications’ capability to deliver complex mechanical replacement schemes in live wastewater environments — safely, efficiently, and to the highest quality standards.