Search
Nominate/Submit Case Studies
Job Board

JK Fabrications Ltd

Burstow STW – ROTANOX Tank System

Design, manufacture, and installation of the new ROTANOX Tank System.
By: JK Fabrications Ltd
Published: October 31, 2025

Burstow STW - CASS (Cyclic Activated Sludge System) Plant

Background

JK Fabrications Ltd was contracted by Galliford Try Infrastructure as part of the Thames Water Burstow Sewage Treatment Works (STW) Upgrade Project to deliver a new ROTANOX Tank System.

This complex project formed part of Thames Water’s broader programme to improve treatment efficiency, capacity, and environmental compliance at the Burstow facility.

JK Fabrications’ role included the detailed design, manufacture, supply, delivery, installation, testing, and commissioning of the complete ROTANOX Tank System, incorporating multiple process and structural elements, mechanical systems, and instrumentation.

Objectives

  • Provide a complete turnkey solution for the ROTANOX Tank System, from design through to commissioning
  • Deliver all components in compliance with Thames Water and WIMES specifications
  • Ensure efficient, durable, and low-maintenance operation of the treatment process
  • Integrate the new systems seamlessly within the existing site layout
  • Achieve safe, high-quality delivery with full traceability, testing, and compliance documentation

Scope of Works

JK Fabrications’ package included all works associated with the ROTANOX Tank System, aeration systems, scraper bridges, and access steelwork, including:

  • Aeration System (FBDA System)
  • Aeration System (FBDA System)
  • FST Scraper Bridges
  • Access & Walkway Steelwork
  • Instrumentation
  • Testing & Commissioning

Project Challenges

The Burstow STW ROTANOX Tank System was a large-scale, multi-disciplinary project requiring careful coordination between civil, mechanical, and electrical contractors.

The installation of large GFS tanks, aeration grids, and structural steelwork required precise sequencing and lifting operations, managed under stringent safety controls.

To mitigate risks, JK Fabrications implemented comprehensive risk assessments, method statements, and lifting plans, developed in conjunction with Galliford Try’s project team.

Additionally, the integration of mechanical and electrical systems — including aeration blowers, scraper controls, and instrumentation — required close collaboration between fabrication, electrical, and process engineering disciplines to ensure seamless system performance.

Outcome

JK Fabrications successfully delivered the design, fabrication, installation, and commissioning of the new ROTANOX Tank System at Burstow STW.

The completed installation met all Thames Water standards for mechanical, electrical, and process performance.

The new basins, aeration system, and scraper bridges now operate as a fully integrated treatment process, delivering enhanced biological treatment efficiency and supporting Thames Water’s long-term environmental compliance targets.

This project demonstrates JK Fabrications Ltd’s capability to deliver complex, high-value turnkey process installations safely, efficiently, and to the highest technical standards — reaffirming our position as a trusted engineering partner within the UK water industry.

Ringsend Sludge Line Enhancement (2025)
Delivering capacity, resilience and sustainability at Ireland’s largest sludge processing facility
case-study
Beckton STW (2023)
Beckton Sewage Treatment Works (STW) is the United Kingdom’s largest STW serving a population equivalent of over four million. The AMP7 project is a major £185m investment to increase the site’s treatment capacity for growth, by a population equivalent of 200,000, by extending the existing activated sludge plant (ASP). Beckton STW will receive stormwater from […]
case-study
Lee Road Water Treatment Plant (2023)
Lee Road Water Treatment Plant (WTP) provides approximately 70% of Cork City’s total treated water supply. Water is taken from the River Lee, treated and then pumped to reservoirs in the north-west of the city through a system of rising mains. Water is distributed to consumers throughout the city via a network of gravity distribution […]
case-study
Ringsend WwTP: Phosphorus Fixation (2023)
Resource recovery for agricultural fertiliser use, while protecting the water quality in Dublin Bay
case-study
Bicester STW (2022)
In recent years the Oxfordshire town of Bicester had undergone significant growth in its population with a further potential growth of 37% in the near future. In late 2019, Thames Water implemented the need for a growth scheme to upgrade various elements of the works to accommodate the forecast population increase. Bicester STW is a […]
case-study
Ringsend Main Lift Pumping Station (2021)
Ringsend Main Lift Pumping Station (MLPS) is located at Pigeon House Road, Ringsend, Dublin 4 and forms a critical part of the overall Dublin Drainage Network. It is operated by Dublin City Council and is under the joint control of the Local Authority and Irish Water. The MLPS pumps unscreened, unfiltered wastewater from the city […]
case-study
Brentwood STW (2020)
Brentwood Sewage Treatment Works (STW) is one of Thames Water’s medium sized treatment works. The site is located to the north-east of London between Harold Wood and Brentwood in Essex. The STW treats foul water from the catchment serving West Brentwood, Warley and Pilgrims Hatch. It currently serves a population of 36,500 which will increase […]
case-study
College Avenue Contact Tank (2020)
South East Water’s College Avenue Water Treatment Works in Berkshire supports the Maidenhead water supply infrastructure. It extracts raw water from three boreholes and three chalk wells, which is then dosed with sodium tripolyphosphate (STPP), aerated, passed through granular activated carbon (GAC) absorbers, and finally injected with sodium hypochlorite to super-chlorinate it before entering the […]
case-study
Oldham & Royton Integrated Strategy (ORIS) (2020)
United Utilities is the regional water company for the North West of England, delivering water and wastewater services to 7m people from Cheshire to the Scottish border. Oldham WwTW and Royton WwTW are two major wastewater treatment works located in Oldham, to the north east of Manchester. The Oldham and Royton Integrated Strategy (ORIS) project […]
case-study
  • Company Profile
  • Post Description
  • Photo Gallery
  • References
  • Mini Case Studies
Contact Info
Unit 5, Derryboy Road, Carnbane Business Park, Newry, Co. Down BT35 6QH
028 3025 2142
Email Us
Visit Website