Wastewater Treatment Plant Structural Modifications

Introduction

Incon was engaged to provide structural engineering design and verification services for modification works at the Bolivar Wastewater Treatment Plant (BWWTP). The scope focused on enabling safe demolition, lifting, and structural alteration of reinforced concrete infrastructure within an operational treatment facility.

Project
description

The project involved the cutting, lifting, and removal of reinforced concrete elements within primary sedimentation and recirculation structures to facilitate refurbishment and operational upgrades.

As indicated in the structural drawings, the works included:

Concrete wall and slab sections up to 200mm thick
Removal of large precast/in-situ blocks ranging from:

~1.1T to 2.4T individual elements

Defined cut lines and staged demolition zones
Integration with existing hydraulic and process infrastructure

The methodology required precise coordination between structural stability, lifting operations, and temporary works systems.

Challenge

Large sections (up to ~2.4 tonnes) required safe lifting design without overstressing remaining structure or lifting equipment.
Partial removal of walls and slabs risked instability and unintended load redistribution.
Required integration of propping systems within confined operational environments.
Works needed to be undertaken without disrupting critical wastewater treatment processes.

Solution

Incon delivered a robust, construction-focused engineering solution integrating structural analysis, lifting design, and temporary works systems:

Developed controlled cutting methodology aligned with structural behaviour, ensuring:

Stability of remaining structure
Safe segmentation of concrete elements
Efficient removal sequencing

Engineered lifting strategies for heavy concrete blocks, including:

Verification of lifting points and rigging arrangements
Coordination with site lifting equipment

Utilised SYS30 propping system with capacities up to 300kN axial load to:

Support partially demolished structures
Maintain load paths during staged removal
Provide adjustable and modular support solutions

Key Engineering Value Delivered

Enabled safe removal of large structural elements within a live treatment plant
Eliminated risk of progressive or unintended structural failure
Delivered practical and buildable demolition methodology
Optimised use of modular propping systems, improving construction efficiency
Reduced downtime and disruption to critical wastewater operations
Provided integrated engineering support across design, demolition, and lifting

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