Supply Chain - Treatment Works Products/Services - Overhead Cranes & Hoists

In recent times Seagahan WTW has faced ongoing issues including:

Unaddressed, these deficiencies could pose risks to regulatory compliance, limit future growth capacity, and increase the potential for Cryptosporidium contamination.

The Seagahan WTW Treatability Improvements Project has implemented a series of targeted upgrades to enhance water quality, improve operational resilience and maintain compliance. Key interventions included:

These upgrades are informed by a treatability appraisal conducted by Arup, which identified critical shortfalls and recommended improvements to ensure the facility could meet current and future regulatory standards.

NI Water engaged Arup and Murphy DAWSON-WAM (MDWAM) early in the project through an Early Contractor Involvement (ECI) approach, fostering a collaborative environment that allowed the project to evolve efficiently. As Principal Contractor, Murphy DAWSON-WAM, supported by strong coordination across all parties, successfully delivered the project on time and within budget. Arup played a dual role, providing NEC Project Management and Supervision throughout the construction phase, while also leading design reviews and approvals. Their involvement extended to managing stakeholder engagement within NI Water and liaising with external bodies such as the Department for Infrastructure.

A key success factor was the strong working relationship developed with NI Water’s Operations, which enabled a clear understanding of practical operability challenges. This collaborative approach informed strategic decisions around infrastructure layout, including pump and panel positioning, freeing up space for storage and maximising the use of existing buildings. These efforts not only streamlined project delivery but also ensured the long-term resilience of water treatment at Seagahan WTW.

ECI with MDWAM and Arup enabled a collaborative and informed approach from the outset of the project. Arup provided up-front technical input through treatability studies, which were instrumental in shaping Business Case submissions and developing focused Basis of Design reports. This proactive engagement supported scope progression and ensured a robust design strategy. Throughout the process, NI Water stakeholders were actively involved in decision-making, fostering transparency and alignment across all phases of delivery.

As designs evolved, a number of design review workshops were held which involved the use of walkthrough models to highlight pinch points and process walk-throughs.

Preference was for the new soda ash storage silo to be located indoors, restricted space for which was determined in the existing GAC building. MDWAM introduced innovative methods, including a 3D scan of the existing GAC building, to validate the feasibility of initial design proposals and facilitate the reuse of existing storage space. The volume and design of the storage silo were influenced by these constraints. The 3D scanning of the existing GAC building was instigated in the absence of record drawings, with new equipment designed to fit head height constraints and roller door access for installation.

A key design decision identified during a design review meeting was the introduction of a structural steel mezzanine platform level to locate the new MCC as floor space was limited.

During the initial investigations, the team identified gaps in the existing information relating to original structures, highlighting the need for further exploration. In several instances, monitoring data was unavailable, so dosing pump and process design had to be guided by SCADA trend analysis where possible. Temporary instruments were also set up during ECI to capture critical analytical data that was otherwise missing. These proactive measures ensured that design decisions were grounded in accurate, site-specific information, ultimately enhancing the reliability and efficiency of the final solution.

The project was delivered within a live operational environment, requiring meticulous planning and coordination to ensure continuity of service and safety. Construction on site began in December 2023 and completion was at the beginning of July 2025. The works were sequenced to minimise disruption to ongoing treatment operations, with close collaboration between the design, construction, and operations teams throughout. A key inherent risk exists when interfacing with existing operational works, live instruments and electrical assets, and this collaboration and careful planning helped to ensure no negative effect on network assets or output during the upgrade.

Early challenges included the failure of legacy equipment originally earmarked for reuse, such as manganese blowers and seized valving arrangements. These issues were addressed through rapid redesign and procurement, ensuring the programme remained on track. Spatial constraints within the site presented further complexity, particularly during the construction of the new dosing chamber and associated pipework diversions. Temporary works and phased excavation strategies were implemented to maintain access and operational integrity.

Modifications to the clean water tanks (CWT1 and CWT2) were carried out under confined space protocols. The installation of actuated valves and bell mouth fittings required innovative approaches due to restricted access openings. Sequencing was critical, with CWT2 brought back into service prior to converting CWT1 into a dedicated un-chlorinated backwash tank.

All works were delivered on a live site, with embargo periods and planned maintenance activities carefully managed. Temporary dosing systems were installed to facilitate safe changeovers, and effective stakeholder engagement with NI Water operations teams ensured that risks were mitigated and service continuity maintained. The new soda ash plant was commissioned in April 2025 and has since been used as the pH controlling process, taking over from the old system.

The project also included the installation of a new potable water supply to the site, with future-proofing measures incorporated to support additional connections. Engagement with DfI Roads and NI Water Distribution Teams ensured compliance and coordination with wider infrastructure planning.

As part of the project, several process-driven improvements were implemented to enhance operational reliability, chemical dosing accuracy, and overall treatment efficiency.

Soda ash system upgrade: The existing soda ash silo was experiencing structural issues and material bridging, leading to inconsistent dosing. A new soda ash system was installed, comprising a silo with integrated shakers, blowers, and a batch tank. A third mixing/maturation tank was introduced to stabilise pH levels and eliminate dosing spikes. Strategically positioned at the opposite end of the building, it also shortens suction lines and improves soda ash solubility. This upgrade ensures consistent material flow and improved pH control, particularly important given the variable pH levels observed due to temperature fluctuations in Seagahan Reservoir.

Potable water protection measures: To prevent back siphonage and protect potable water quality, the supply to the backwash tank was removed following its conversion to an un-chlorinated backwash tank. A new supply line was established from the main distribution network, ensuring compliance with water safety standards.

Centralised control via MCC panels: Motor Control Centre (MCC) panels were installed to provide centralised control of all newly commissioned equipment. This integration enhances operational oversight and simplifies maintenance procedures.

Efficiency gains in backwashing: The transition to unchlorinated water for backwashing has led to reduced chemical wastage and improved backwash efficiency, especially during periods of poor water quality. This required careful reconfiguration of valving arrangements and blanking off interconnections between tanks to prevent contamination of clean water leaving the site.

Flow monitoring & chemical dosing control: A dedicated flow meter chamber was constructed to monitor flow rates of orthophosphate and chlorine dosing. The flowmeter also interfaces with an actuated valve to regulate the filling of CWT1, now designated as the backwash tank. This setup allows for precise control of chemical dosing and tank filling operations.

To protect operatives, the chlorine and orthophosphate are installed in separate chambers to reduce the risk during leaks. This item was identified during a hazard identification meeting.

Hydraulic improvements: The upstand level of CWT2 was increased to enhance hydraulic head, supporting improved flow dynamics across the system. An actuated valve was installed to prioritise flow between the backwash line and CWT2, ensuring that neither system is starved during simultaneous operations.

Water recovery gains: The backwash system was previously a bottleneck to reliable output, following review a hydraulic restriction in the lamellas was identified and addressed which allowed a greater flow to pass through them to reach their design capacity. This improved the overall efficiency and removed the bottleneck, providing headroom in the dirty wash water system and ultimately providing the works with more frequent backwashing facilities.

The Seagahan WTW Treatability Improvements Project incorporated a range of innovative and sustainable measures that enhanced delivery and long-term operational performance. By maximising existing assets and deploying efficient technologies, substantial carbon and financial savings were achieved, both in construction and ongoing operation.

A 3D scan of the GAC building was undertaken to address the absence of reliable as-built records. This enabled accurate coordination with the BIM model and informed the design of new equipment, including a bespoke mezzanine platform for the MCC panels, optimising use of available space.

Sustainability was embedded throughout the project. Excavated material was reused on-site for landscaping and reprofiling, eliminating disposal costs and reducing carbon emissions. Modular blocks were re-purposed for use on other sites, supporting circular economy principles.

The introduction of a third process tank and the use of un-chlorinated water for backwashing improved chemical efficiency and reduced waste, particularly during periods of algal blooms. Additional measures included the installation of a spill tank with integrated safety features and the design of dosing skids with enhanced access and flushing capabilities.

These innovations supported efficient delivery, reduced environmental impact, and aligned with NI Water’s long-term sustainability goals.

The project exemplifies sustainable infrastructure delivery, with substantial environmental and financial benefits realised through three key initiatives:

Overall, the combined impact of these measures in the first year is estimated to deliver a total carbon saving of 64 to 105 tonnes of Co2e and a cost saving of between £351,216 to £502,432.

The Seagahan WTW Treatability Improvements Project was successfully delivered on time and within budget driven by early contractor involvement, innovative design solutions, and a shared commitment to operational excellence and sustainability. With this project NI Water has been able to enhance operational efficiency, enable real-time monitoring via advanced SCADA telemetry, and has future-proofed the system for further instrumentation upgrades. Collaboration between the client, project manager, contractor and other key stakeholders was central to the execution of the project and its overall success.

The primary challenge driving this project was the inadequate storm volume capacity at Ramsey WRC. The existing storm tank could only hold 260m³, far below the required capacity set by the Environment Agency (EA).

Failure to increase the on-site stormwater storage capacity would result in a consent failure leading to the risk of environmental harm and regulatory penalties for Anglian Water.

Additionally, the site’s existing flow to full treatment infrastructure was outdated and in need of major repair and upgrade. The current system could not handle the additional flows required to meet future population growth and environmental obligations. Without intervention, Ramsey WRC faced operational inefficiencies and potential breaches of discharge permits.

To overcome these issues, Anglian Water tasked the @one Alliance to design a dual-scheme solution to address the stormwater storage and FtFT issues.

The new storm tank designed to significantly increase storage capacity and reduce overflow risk during heavy rainfall events. The new tank is 11.1m in diameter and 8.47m high. This provides an additional 693m3 of storage capacity bringing the total volume of stormwater storage to 953m3. This upgrade ensures compliance with Environment Agency requirements and future-proofs the site against climate change impacts and population growth.

To improve operational efficiency and safety, the design incorporates external dry well submersible pumps for automated cleaning. This innovation eliminates the need for manual cleaning and access platforms, reducing health and safety risks for maintenance teams.

Furthermore, the stormwater storage tank has been carefully integrated into the existing infrastructure, optimising the limited site footprint and minimising disruption during construction. This approach allowed the project team to deliver a high-capacity solution without extensive civil works or compromising ongoing operations.

The second element of the project focused on increasing the site’s ability to treat incoming flows during peak conditions.

Modular side-stream: Anglian Water implemented a modular side-stream solution supplied by Siltbuster Group, which offers flexibility and scalability within the constrained site layout. This system includes:

These technologies work in harmony to deliver robust treatment performance even under challenging conditions.

Supporting this advanced treatment process are associated pumps, flow splitters, and access platforms, ensuring smooth operation and ease of maintenance.

Tertiary solids removal: To further enhance effluent quality, the project has incorporated tertiary solids removal (TSR) through twin-stream pile cloth filters and disc filters from FLI Water Ltd, which provide an additional layer of protection for local watercourses.

Power supply: Recognising the increased power demands of these systems, the upgrade also includes a 315kVA electrical power enhancement, installation of a new LV switchboard kiosk, and integration of telemetry systems for real-time monitoring and control.

Collectively, these improvements enable Ramsey WRC to handle an additional 20 litres per second (l/s), bringing the total FFT capacity to 89.4 l/s, while ensuring compliance with stringent environmental standards.

Delivering this complex project posed several significant challenges that required innovative solutions and careful planning.

Coordinating these systems demanded robust design and commissioning strategies. The team mitigated risks by collaborating closely with specialist suppliers, ensuring seamless integration and reliable performance across all components.

The successful delivery of the Ramsey WRC upgrade was underpinned by a highly coordinated and collaborative supply chain strategy. Given the complexity of the dual-scheme approach, combining storm tank capacity upgrades with advanced flow to full treatment (FFT) enhancements, the project required contributions from multiple Tier 2 contractors and specialist suppliers, each playing a critical role in achieving the technical and regulatory objectives.

Work commenced in August 2024 and at the time of writing (January 2026) is scheduled for completion in the upcoming months; ensuring that all regulatory deadlines are met without delays.

The Ramsey Water Recycling Centre upgrade stands as a clear demonstration of Anglian Water’s commitment to resilience, regulatory compliance and environmental stewardship. By investing £10m into advanced treatment technologies and storm capacity improvements, the project not only addresses immediate operational and regulatory challenges but also future-proofs the site for AMP8 and beyond.

This strategic investment ensures that Ramsey WRC can continue to meet the growing demands of population increase and the tightening environmental standards that govern water recycling operations.

The flow to full treatment element of the investment is on track to achieve an 77% reduction against Anglian Water’s capital carbon baseline, which is key to supporting Anglian Water’s commitment to reaching a net zero organisation by 2030.

In 2022, Glanua Group was awarded a contract under the AMP7 WINEP Programme to design and construct a tertiary solids removal (TSR) plant incorporating Evoqua’s CoMag® technology from Xylem Water Solutions.

At £36.5m, the project represents a significant CAPEX investment and a key advancement in wastewater treatment performance, delivering enhanced solids and phosphorus removal efficiency.

By integrating innovative and sustainable treatment processes, the scheme will comply with stringent environmental standards and contribute to improved effluent quality and environmental protection.

The construction and MEICA installation of the TSR plant have been completed, and the project commissioning team is now operating the system in preparation for reliability testing and handover. The CoMag® TSR process is consistently achieving phosphorus concentrations well below the consent limit of 0.3 mg/l, demonstrating robust process performance and operational reliability.

The upgrade works includes five Flygt channel impeller pumps from Xylem Water Solutions to lift current final effluent to the TSR plant, via a distribution chamber, where flow from five inlets splits evenly into two streams.

Ferric sulphate is dosed upstream of the CoMag® reactor and continuously mixed to encourage the formation of flocs. A magnetite slurry and a poly-acrylamide solution are also dosed and mixed to add weight to the flocs, enhancing their settlement in the two 23m diameter clarifiers.

The scheme also includes the provision of an upstream ‘primary’ ferric sulphate dosing system, which is integrated into the existing treatment process. This adjusts the pH and phosphorous levels upstream of the TSR plant, allowing optimisation of the CoMag® system.

Blackburn Meadows TSR Plant - Courtesy of Glanua

The CoMag® system is a ballasted separation and recovery process. It utilises magnetite alongside coagulants to create a ballasted flocculation system, thus enhancing settling rates and increasing the performance of the wastewater treatment plant. The high-density, magnetite ballasted floc flows into a compact high-rate clarifier. The clarifier includes baffle plates to dissipate the velocity of the inflow, encouraging optimal settling, and a rotating rake directs sludge into the hopper.

The remaining 30% of the sludge is processed through magnetite recovery system, which includes an inline, high-speed shear mixer where the magnetite is separated from the floc. The resulting two-part slurry is then passed through a magnetite recovery drum.

The permanent and stationary magnets inside the drum help to capture and reuse more than 99% of the magnetite, meaning that once primed, the CoMag® operates with very low magnetite consumption and low OPEX.

The sheared sludge, minus the magnetite, flows into the wastewater pumping station, where it is returned to the main WwTW via a new rising main, discharging immediately upstream of the primary settlement tanks.

Originally, the WwTW’s final effluent discharged to the River Don via twin 1400mm brick-built culverts, buried at 6m cover to crown, which are believed to have been constructed in the Victorian era. A crucial and complex part of the scope was to excavate around and break into the culverts to enable flow diversion to the TSR. This required significant temporary works in the form of over pumping the final effluent and allow the culverts to be drained and isolated.

The number of shutdowns and over-pumping operations were minimised due to refinement of the construction sequencing and programme, reducing environmental risk exposure associated with temporary over-pumping installations. This accomplishment followed a huge effort by Glanua Group, Selwood and Yorkshire Water, and was completed under the guidance of, and in liaison with, the Environment Agency.

The condition of the culverts was largely unknown prior to excavation, with limited information available from trial holes. There were concerns about how the vibration from the sheet piling works would affect the culverts, during the installation of the cofferdam. As such, the temporary works design specified the use of silent piling technology with pre-augering to loosen the dense granular strata identified in the ground investigation.

Once excavated and broken out, temporary steel supports were affixed to the structural blinding, and mild steel pipework was installed to reintroduce flows, and decommission the over-pumping.

The TSR feed pumping station, utilising a cast in situ design, was constructed by Hernon ME around the temporary pipework, reducing the reliance on over-pumping from approximately six months to six weeks.

The Blackburn Meadows project was delivered through BIM 360, was Glanua Group’s Common Data Environment (CDE) and Information Delivery platform. This ensured that all project information was structured, reviewed, and approved within a controlled digital environment aligned with Glanua’s ISO 9001 Quality Management System and industry best practice for Digital Project Delivery.

Effective digital processes were central to how the project was delivered. By using the CDE, the flow of information was structured, auditable, and transparent across all design and delivery teams. This enabled consistent adherence to Glanua’s BIM and information management principles, ensuring the right information reached the right people at the right time.

Autodesk Revit was used for 3D modelling and drawing production across all disciplines (civil, structural, mechanical and electrical), which enabled integrated and coordinated design deliverables. The built-in review and approval workflows within Autodesk BIM 360 supported rigorous checking, digital mark-ups, and traceable approvals throughout design and construction.

The model coordination module was used by the entire project team and central at key design and construction milestones. Digital coordination reviews, HAZOPs, and ALM reviews were all conducted within the model environment to provide clear visual context. This approach improved decision-making, enhanced safety in design, and identified construction efficiencies, directly supporting programme delivery and quality outcomes.

Through the asset module in BIM 360, critical asset information was digitally captured and managed to support data-driven decision-making throughout the project. Each asset’s installation, commissioning and testing status was tracked and updated with specific information required to meet the client’s asset data handover.

By analysing this data, the project team was able to identify the most efficient point in the delivery process to input the information required on the client’s platform, ensuring accuracy and consistency were married with efficiency.

By beginning with the end in mind, operation, maintenance, and handover information was accurately collated throughout delivery.

Relevant commissioning checklists were also linked to these assets, allowing the commissioning team to directly access and complete commissioning data within Glanua Group’s Common Data Environment.

A total of 187 precast panels were manufactured, shipped and placed during construction of four of the five main structures which has shown a significant carbon saving, compared to the use of an in situ concrete solution.

A calculation from FLI Precast Solutions demonstrated that the cement content, reduced by 50% and replaced with ground granulated blast furnace slag (GGBS) in the design mix for the precast panels, would provide a total CO2e saving of 137.2 tonnes. By comparison, this saving is shown as the equivalent of not driving for over 1.1 million kilometres, or the carbon absorbed by 3430 trees growing for 10 years.

For the remaining in situ slabs and structures, the concrete volumes have been reviewed and rationalised where possible. For example, the proposed perimeter wall was changed from a design containing 0.80m3 of concrete per linear metre to an equally effective design containing just 0.16m3 per linear metre, an 80% saving of concrete on this item of scope, demonstrating that a critical review in a small area can yield a significant impact.

The five TSR feed pumps are controlled from large variable speed drives (VSDs), which are housed in individual sections of the main site MCC. Whenever a pump is running, an extractor fan pulls 3,760m3/hr of air though each VSD section, expelling it directly to the atmosphere external to the kiosk.

Replacement air is drawn into the kiosk through 30 vents in the kiosk wall. Whilst this is fine in summer, during winter months, the kiosk would require significant heating to avoid condensation forming inside the panels. It was calculated that 90kW of electric heaters were required in the kiosk to maintain an internal temperature of 10°C, when the ambient external temperature was -5°C.

It was considered too wasteful to provide so much heat, just for it to be exhausted to the atmosphere, in addition to the OPEX associated with this level of heating. In conjunction with supply chain partner, Air Technology Systems (ATS Climate), the VSD exhaust system was redesigned to include an air diversion and recirculation option, which automatically changes over based on temperature set points within the kiosk.

During a recirculation scenario, air is not extracted from the kiosk, meaning there is no low pressure causing cold air to be drawn in to the kiosk, eliminating the requirement for specialist heating of the kiosk beyond standard building services.

The introduction of the TSR plant at Blackburn Meadows is a significant investment by Yorkshire Water in the environmental protection of the River Don and the surrounding area. By embracing the new CoMag® technology, Yorkshire Water have signalled their intent to support innovative solutions when complying with tighter water quality consents to protect the environment.

Glanua Group would like to thank Yorkshire Water and all delivery partners involved who have collaborated to bring project together through proactive and solution-orientated design and build engineering.

The town and immediate area are currently served by a sewage treatment works established at the turn of the last century and upgraded over the years. It is located beside the River Wey, to the north of the A3 trunk road and north of Guildford town centre. It lies just south of Slyfield Industrial Estate. The current STW has a capacity to cater for a population equivalent of around 120,000.

Guildford Borough Council’s Local Plan adopted in 2019 allocates a site to the west of the River Wey wrapping around the eastern side of Slyfield Industrial Estate for mixed use development. Part of the 40 Ha allocated site is currently occupied by the existing sewage treatment works.

Weyside Urban Village is a mixed-use regeneration project which will provide some 1,500 new homes, new community facilities, Gypsy and traveller pitches and 6,500m2 of additional light industrial and trade space. 11Ha of the site are allocated for waste management purposes. The plans include a new council depot, a public recycling centre and a new, relocated sewage treatment works.

In order to bring the development site forward, within the plan period to 2034, Guildford Borough Council (GBC) have entered into partnership with Thames Water Utilities Ltd (TWUL) to build the new STW as the first phase of the redevelopment. The new location is slightly further north on the eastern edge of the Industrial site and is a brownfield site, formerly a gravel quarry and subsequently a landfill tip.

The new sewage treatment works allows for an increase in capacity to serve a population of 125,000 allowing for predicted population growth in the town and surrounding area as well as more stringent effluent discharge standards.

The new site also includes areas within the new works for future expansion and increased treatment capacity as need arises.

The scheme to build a new sewage treatment works (STW) in Guildford is now mid-way through construction. This article provides an update to the project following on from previous articles published in Water Projects. In 2023, Enpure Ltd’s Project Delivery Director Shaun Christopher described in detail the process and assets being provided in the new works and in 2024, Dan Russell, BAM’s Operational Lead, gave an update on the progress of the project one year into the construction.

This article also covers some of the planning considerations and requirements for the scheme.

In 2021 TWUL awarded a contract to a BAM-Enpure Joint Venture to design, build and commission a new STW for Guildford, and once operational, to de-commission the existing works. BAM-Enpure Joint Venture (JV) is a non-integrated Joint Venture, formed specifically to combine experienced civil engineering contractor BAM with the process engineering MEICA specialism of Enpure, to deliver a turnkey solution for TWUL.

Construction began in the spring/summer of 2023 with BAM undertaking design and construction of the civils works and Enpure providing process and MEICA design and installation. BAM have employed Arcadis as their main civils designer and the JV has let a number of specialist sub-contractor design packages alongside.

The project consists of the following:

A detailed description of the process and assets being installed is set out in the previous Water Projects article published in 2023.

The new site comes with additional challenges in that it is brownfield site formerly used for gravel extraction and then landfilled through the 1960s, 70s and 80s, with mainly domestic and some commercial waste. The site is classified as a waste development such that the local planning authority is Surrey County Council (SCC).

The planning permission granted was subject to a number of conditions and commitments, not only relating to the siting and development of the STW itself such as visual impact, odour, noise and traffic generation, but also to the remediation and reuse of the landfill site. Plans and construction methods needed to ensure that there was no temporary or permanent environmental damage to the surrounding area as a result of the impact on or disturbance of the buried waste material and that operatives working on the new STW were protected from any ill effects of the landfill during operation of the site. The landfill also poses particular constraints and hazards during the construction phase.

The strategy for the site was to leave as much of the landfill waste in situ and build above and through the waste. A detailed remediation strategy formed part of the planning requirements. The plan set out how the construction and operation phases of the project would manage issues of ground water and ground gas, potential ground water contamination and leachates, contaminated solid material including asbestos, and short- and longer-term settlement of the landfill.

Dan Russell’s case study in Water Projects 2023 provided a detailed description of the use of a combination of ground improvement and foundation techniques, which consisted of:

Figures 5 (below) show the historic gravel extraction map and depth of landfill determined by ground investigation - both images were extracted from the project’s Detailed Remediation Strategy.

However, the impact of the waste material goes beyond its bearing capacity. The site was already being subject to long term monitoring for ground gas and groundwater quality by Thames Water to provide a baseline for the project. Additional boreholes were sunk and a Groundwater & Ground Gas Monitoring Plan was approved by the local authority. Daily and continuous automatic remote monitoring was undertaken during the ground improvement and excavation phases with trigger levels set and exceedances reported back to SCC and a requirement for quarterly summary reporting. Monitoring will continue during commissioning of the site at less frequent intervals.

Asbestos: Asbestos had been discovered in a third of samples taken during the ground investigation and so a monitoring regime was established. Air sampling around the perimeter of the site ensured any airborne particles were detected and works could be stopped if necessary. Proximity asbestos monitoring and identification of asbestos material in excavation has also been used extensively during excavation across the site. The project used Socotec to undertake asbestos monitoring and testing.

Ground gas: A ground gas protection design has been necessary to reduce risk of ground gas entering occupied buildings, kiosks, tanks and chambers where operational or maintenance access is undertaken. A ground gas design protection strategy was set out by Arcadis with PAGeo Contracting Ltd providing expert advice and a detailed ground gas design, PAGeo then supplied gas dispersal matting, venting components and gas membranes. Both the strategy and the detailed design for ground gas protection have been submitted to and approved by SCC.

Independent verification of the gas protection installation has been provided by MTS Ltd as verification of the installation and subsequent reporting to SCC is a planning condition.

Surface drainage: On-site surface drainage has been carefully designed such that new impermeable areas are positively drained to the site drainage system to remove the risk of a spill causing environmental pollution. This surface water is then fed into the inlet pumping station for processing through the works. As the permeable area of the site has been greatly reduced this also significantly reduces leachate mobilisation.

Biodiversity: Another planning condition is the provision of Biodiversity Net Gain (BNG). In conjunction with GBC, the project provides 10% net biodiversity gain by use of on-site planting and off-site enhancement of the land directly to the north of the new STW. A Site of Natural Green Space, biodiversity enhancements to an area of farmland, and a marshy meadow along the River Wey are being provided.

The Environment Agency have also constructed a new fish pass in this area allowing fish to migrate around Old Bucks Weir.

Guildford STW: Civils works supply chain - key participants

As of summer 2025, civils works are nearing completion and MEICA fit out has started.

The installation of piled supports has been undertaken, and all major structures are complete. Installation of the below-ground pipework and buried ducting is in progress and the welfare building is watertight and available for equipment installation. Moving towards installation of MEICA equipment, the water testing of structures started in the February of 2025.

Steel staircases and high-level walkways are mostly complete. The inlet screens and grit removal system are in place. GRP tanks for sludge processing are being installed and many control kiosks are in place. Electrical supply buildings are near completion.

MEICA work commenced in February 2025, overlapping with completion of civils to maximise programme efficiencies. Designed alongside the civils elements of the site, the MEICA installation has taken place apace with the first bridges on the final settlement tanks attached, the larger glass coated steel tanks for the sludge area in place, and generators and some kiosks have been installed.

BAM has started the installation of the above-ground pipework and cable pulling in buried ducts, and the fit out of control rooms will commence shortly. Construction of MCC basements has been completed and two of the three MCC kiosk, and power supply and distribution works are nearing completion.

A 1.5m diameter gravity tunnel, 1.5km long, transfers flows from the existing works and intercepts minor sewers en route. There are six shafts along the tunnel route, some of which act as junctions between the new tunnel and the existing sewers. Shafts were sunk by Joseph Gallagher using the caisson method and the tunnel was driven between them using a full-face tunnel boring machine, (named Daphne by a local school). The tunnel and shafts were completed in 2024 and the final work remaining are the completion of the large inlet pumping station (IPS), shaft (E2) at the new works and connection of Guildford’s main sewer to the head of the tunnel, which will allow all flows to be diverted to the new tunnel.

The new inlet pumping station (IPS) is a 12.5m diameter shaft with a depth of 17m, which houses six pumps with the capacity to lift flows of around 2,500 l/s from the tunnel entry, at the base of the shaft, to the inlet works where all flows are screened. The shaft is complete except for the internal walls and installation of penstocks which allow isolation of half the well at any time for maintenance of the pumps. This will be completed in the autumn of this year.

Two storm tanks provide a combined capacity of approximately 8 million litres to which flow can be diverted to temporarily hold sewage arriving at the new works should flows exceed the capacity of the works. Constructed onto in situ bases, the walls of the storm tanks were prefabricated, placed and post-tensioned by A Consult Ltd.

The inlet works and larger chambers were entirely cast in situ due to lack of repeatable sections and logistics. In situ concrete work for these was undertaken by Kelly Formwork. The inlet screens have been installed and walkways are in place.

Screened flows from the inlet works will then pass through primary and secondary treatment tanks comprising rectangular primary settlement tanks (PSTs) and activated sludge plant (ASP) tanks. The walls for these tanks were designed and supplied by FLI Precast Solutions Ltd and installed by BAM and DJ Civils Ltd on in situ bases prepared by Kelly Formwork Ltd. These tanks are complete with pipework being fitted and the ASP has commenced water testing.

To ensure watertightness of the larger rectangular tanks, Heidelberg Materials and Sika’s concrete technology were used.

Concrete containing Sika WT-200 P was utilised for the PSTs and the ASP. Sika WT-200 P is a combined water-resisting and crystalline waterproofing admixture used to reduce the permeability of concrete, making it suitable for water retaining structures.

Gas protection has been laid under all large tanks. Materials were supplied by PAGeotechnial Ltd and verified by MSL Ltd. Void former mating laid on a bed of single grade 40mm stone provides a preferential escape path for ground gases and is connected to vents at the tanks periphery allowing ground gases to vent to atmosphere.

These tanks are not habitable spaces and only require a dispersal system to discourage any build-up of gas below the large tank bases.

The four final settlement tanks were also precast, supplied, installed and post-tensioned by A-Consult Ltd onto in situ bases prepared by Kelly Formwork Ltd. The FSTs are complete with bridges and scrapers installed and are currently being water tested.

Following final settlement, flows will pass through final filtration in the tertiary treatment plant before being discharged to the River Wey via new, twin outfall pipes. Civil construction is complete and MEICA installation of cloth pile filters and drums from Eliquo Hydrok Ltd is underway.

The outfall pipework has been fully installed across the water meadow and the headwall has been constructed at the discharge point into the River Wey.

The project also provides a dewatering facility for imported sludge from other small treatment works. This area is nearing completion with the larger coated glass sludge blending tanks in place and the smaller buffer tanks being installed. Gas vent pipes have been installed below the extensive concrete slabs to allow venting of ground gases to the atmosphere.

The sludge belt presses from Kent Stainless Ltd for sludge dewatering and thickening have been installed adjacent to the bases for the elevated sludge cake silos. The silos from Saxlund International have been sized to provide storage of seven days’ worth of processed sludge, which can be discharged to trucks for export from site.

Power supply and distribution infrastructure is now in place. The three MCCs have been constructed in sequence and the first two are being fitted out.

A new welfare building houses the automated systems for running the new plant and controlling effluent quality as well as office and mess space for Thames Water staff and operatives. The building is watertight with cladding being installed and the fit out of building fixtures and plant control equipment is in progress.

Design has utilised a 3D model hosted by Arcadis with each designer adding in modelling information as their design capabilities have allowed. This has enabled precise integration of designers individual input and interrogation of the integrated design

The model is used extensively by engineers on site. 3D modelling has, for example, allowed duct chambers to be precast with precision positioning of cable openings, saving on in situ working and substantially reducing programme on these installations.

To enable the STW to be constructed on the site without the waste being removed a combination of ground improvement techniques have been employed including driven concrete piles, Rapid Impact Compaction, and Vertical Rigid Inclusions.

The Rapid Impact Compaction work undertaken by Cofra was completed in late summer of 2023. From July 2023 to the spring of 2024, to support the larger structures, tanks and main process critical pipelines, 3500 concrete piles were driven through the landfill into the clay. The design and installation of this piling operation was undertaken by Aarsleff Ground Engineering.

In areas where settlement criteria were less critical, but needed controlling (for example roadways and minor pipework), a Vertical Ridged Inclusion (VRI) piling technique was used. The system involves displacement drilling a column in the landfill and filling the void with concrete. This works by consolidating the soil around the pile, transferring load to lower layers, thus increasing bearing capacity and reducing settlement over time.

Since 2024 the installation of VRIs by Foundation Piling has been completed with 7500 inclusions installed across the site. During detailed design, the project was able to remove the need for a load transfer platform above the VRIs across much of the site. This was done by detailed analysis of the 3D model to target differing requirements for support and by reducing inclusion spacings, thereby reducing the expected landfill removal by 37,500m3.

The load transfer platform remains below roads, but pipework sits within the grid of VRIs.

Completion of the mechanical works is expected in the first part of 2026 with installation of electrical and control systems expected to complete in the second part of 2026. Dry and wet commissioning will be undertaken sequentially across the site throughout the coming year, ensuring the new works is ready to commence process commissioning.

The final, and arguably most challenging activity, will be to connect the existing sewer network to the new tunnel, diverting flows from the existing STW to the new STW. A series of interventions will be required to intercept the various sewers, along the route of the tunnel, all the whilst ensuring the new STW is performing within strict limits and the existing STW is able to maintain its performance during the ramp down of flows.

Weather has a major impact on raw water quality. Typically, rainfall increases flow in the river and, with it, turbidity. Colour, an indicator of natural organic matter, reduces in wet weather and increases in drier spells. Climate change has increased the intensity of rainfall, and this reduces the pH of the river water, making control of coagulation, which depends on colour, turbidity and pH, more difficult.

Higher turbidity during storm conditions requires a higher coagulant dose, and this further depresses the pH. This issue has, on several occasions, resulted in a shut-down of the works which struggled to meet treated water quality goals. Southern Water notified the DWI of this process issue and were issued with an improvement notice which required a long-term solution to be implemented by 28 February 2025.

Southern Water engaged Trant Engineering to develop and implement a solution. Trant had a dedicated team at Sandown working on other schemes and had good working relationships with the Southern Water Project Team and Operations. This meant that they already had a good understanding of the problem and were able quickly to propose a solution consisting of chemical storage, pH control and a caustic soda dosing system together with all the associated piling, reinforced concrete plinths, paths, slabs and buried service ducts.

The proposed process solution treated chlorinated process water through dosing with sodium hydroxide within carrier water immediately prior to entering the contact tank. A measured dose is applied to the process, calculated by measuring pH and flow. The dose is then adjusted as required through a process feedback loop to maintain a required target pH set point.

Because of space constraints, the incoming raw water mains had to be diverted. The dosing system required a pH analyser/controller mounted on a backboard with process instrumentation, pressure sensors, level controllers and automatic valves. Carrier water pumps and a water softener completed the dosing package with an adjacent dosing control panel with PLC and HMI.

There were several key challenges. Highly limited space available for the equipment required, extensive buried services, and challenging project delivery timescales to meet the regulatory outputs. Working closely with Southern Water and the established delivery partners Atkins Realis, Chemidose and F W Marsh, Trant’s team was able to complete the necessary Design, HAZOP and ALM process early in 2024.

The design was prepared with programme constraints heavily in focus and incorporated an off-site ready built kiosk with integral floor. This enabled the full kiosk fitout to be undertaken in parallel with the civils work on site and resulted in significant programme improvement. The dosing system was fully FAT tested offsite at Chemidose’s premises.

Space was tight to fit the kiosk on site, and tight within the kiosk to fit the process equipment needed whilst maintaining good access. A collaborative design process and a great team enabled this to be achieved within the constraints. Challenges were encountered on the civils design including unmapped significant pipework and unfavourable geotechnical conditions in the only viable location for the kiosk. The team moved quickly to resolve solutions which required a piled foundation to address the ground conditions and avoid loading the unmapped pipework whilst diversion was resolved.

The civil works and on-site preparatory M&E works were completed in parallel with the dosing kiosk fitout. This combined with the level of offsite fitout and testing substantially minimised the on-site installation period. The dosing kiosk was delivered to site as the civil works were completed, and a limited period of M&E works were required to connect into the existing site process.

Within four weeks of the kiosk delivery, commissioning was able to commence. A successful commissioning period allowed project works to enter active service several weeks ahead of the DWI regulatory date for installation. The project achieved full formal handover well ahead of the DWI regulatory date for commissioning.

By close cooperation throughout the supply chain, commissioning was able to commence within four weeks of the kiosk delivery. Being familiar with the site, Trant’s Instrumentation, Control & Automation (ICA) team was able quickly to integrate the new controls, and the new works was in service and formally handed over several weeks ahead of the DWI regulatory date for installation.

The solution deployment has been successful in addressing the problem of low pH causing a need to shut down the works during periods of heavy rainfall and this success has been welcomed by all parties.