Cessnock Waste Water Treatment Works Upgrade For Hunter Water


Location: Cessnock, New South Wales

Client: Abergeldie Complex Infrastructure, for Hunter Water

Industry: Industrial Construction

Scope: An Industrial Construction project for the design and construction of multiple custom sheds and buildings

Project Background and Benefits

Originally built in 1932, the Cessnock Waste Water Treatment Works was typical of facilities of the time, with similar Waste Water Treatment plants installed at Morpeth, Shortland, and Kurri Kurri. Moving forward to the present day, the Cessnock Waste Water Treatment Works currently services around 32,000 people throughout Cessnock, Aberdare, Bellbird, and Nulkaba.

According to Hunter Water, the upgrade of the Cessnock Wastewater Treatment Works benefits the community throughout the region with updated treatment processes and improved quality of treated wastewater discharged from the site. 

The upgrade will also meet new limits set by the Environment Protection Authority (EPA) and ensures the plant is prepared for future population growth.

Project Overview

With more than two decades of experience in project managing complex infrastructure and heavy industrial projects, Asset Building Systems is New South Wales leading structural steel shed builder. We value the professional, genuine partnerships we have with our clients and broader network. So it goes without saying we were delighted to partner once again with Abergeldie Complex Infrastructure for the Cessnock Wastewater Treatment Works Upgrade Project

This design and construction project was a necessary deliverable for the $25 million upgrade by Hunter Water to improve the Cessnock Waste Water Treatment Works, benefiting thousands of people in the community. 

The much-needed upgrade required a variety of bespoke infrastructure for the wastewater treatment plant. Multiple buildings needed to be designed and constructed, including an Aeration  Blower Facility, a Motor Control Centre (MCC) building, a Chemical Dosing Facilities, a Main Switch room, and a Recycle Storage Tank (RST) Building. All buildings had to comply with specific Hunter Water construction standards. 

Design Considerations

As a design and construct contract, a primary consideration for the Asset Buiding Systems team was to meet the Hunter Water Standard Technical Specifications (STS). Each of the buildings constructed for the upgraded Cessnock Wastewater Treatment Plant needed to meet the specific construction standards. The steelwork (all fabricated in our workshop) had to be ultrasonically weld tested (UT). As a non-destructive testing method, ultrasonic testing has a high sensitivity for detecting the smallest defects and is ideal for detecting flaws and defects without damaging the tested object. 

Further considerations were to ensure the structural steel columns didn’t interfere with pumps that required maintenance and couldn’t hinder the forklift’s access. It was also essential that the building design didn’t conflict with the pumps and piping layout.

The Construction Process

Asset Building Systems are committed to safety and compliance, and these values guide each project’s construction process. Constructing the Cessnock Waste Water Treatment Plant Buildings was no exception:

  • Set out footing bolts according to the footing plan, and survey and chem set the footing bolts
  • Construct the roof frame, safety mesh, insulation, and last of all, the roofing sheet and flashings as one piece on the ground.
  • Stand the columns and bolt to the footings.
  • Lift the roof into place.
  • Fit wall sheeting,  flashings, and vents.
  • For building the block wall buildings – lay the blocks, core-fill with concrete, and then lift the roof into place.

With safety in mind, we built the building roofs on the ground and lifted each one as one whole piece, reducing working at heights and thereby reducing the risk of harm to team members.

Construction Challenges

Aside from the typical challenges of industrial building construction, one of our most significant challenges came from an unexpected source. Looking back, it’s no secret that much of New South Wales suffered unanticipated, record-breaking rainfall throughout 2022. This unprecedented level of rain presented a challenge for much of the community, including construction firms throughout New South Wales. One particularly unique challenge was when 40mm of rainfall hit the construction site – on the very day the roof was lifted. Not a problem for Asset Building Systems – our highly experienced team confidently rose to the challenge and got the job done safely.

Project Outcome

With a commitment to safety and compliance and a focus on delivering on budget and on time, we are pleased to report that Abergeldie Complex Infrastructure is, once again, a happy, satisfied client. We are sure the Cessnock community and surrounding also appreciate the improved quality of discharged wastewater!

Why Asset Building Systems?

Abergeldie Complex Infrastructure selected Asset Building Systems due to our experience with water treatment projects and our proven professionalism and attention to detail. This due care was evident from the development of our design drawings thorough to the thorough completion of comprehensive Work, Health and Safety (WHS) compliance paperwork and safe crane lift plans.

As a repeat client of Asset Building Systems, Abergeldie Complex Infrastructure know we are easy to work with, and we keep our promises. In fact, we are so trusted and respected that more than 50% of our clients either return or are referred via our working network.

Work With Us!

Asset Building Systems are an industry leader in industrial and commercial construction. We are experts in industrial building design, fabrication, construction & project management. Renowned for our fixed-price operation model, more than 50% of our clients are returning or referred through our working networks.

With a commitment to delivering on budget and one time when it comes to commercial and industrial construction projects, you can feel confident you’ve made the right choice with Asset Building Systems.

Contact Us Today For a No-Obligation Quote

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