The project scope included the design, supply, installation and commissioning of the piling requirements for MBBR pad, MBBR, chemical delivery and pond pump pads, process building (including laboratory, MCC and blower rooms) and two MBBR tanks with platform/walkway structure. The plant can treat up to 1,500m3/d. The wastewater effluent is made up from the Katikati township households, as well as trade waste from local businesses.

Our design and build services included the installation of a fine screen compactor, aeration screw blowers, MBBR feed pump station, waste sump pump station and a 49% acetic acid storage tank with a chemical dosing system. We also provided switchboards and PLC panels for both the existing and MBBR plants, a 250 kVA standby generator, below ground PE piping and above ground stainless-steel air and process piping.  

Additional services include instrumentation and control valves, a security system for the new process building, and roadworks such as the development of a chip-sealed ring road for chemical deliveries, widening and sealing of the entrance and the construction of a new pond road.  Apex also completed road repairs and sealing of the existing roadways and landscaping for the new MBBR facility and surrounding areas.

Challenges included complex heavy lifting of two MBBR tanks and a platform/walkway structure into place onsite and the effluent pond diving to insert and remove plugs to the pipe linking two effluent ponds.

This project demonstrates our ability to successfully deliver a large, complex design and construct a Moving Bed Bioreactor (MBBR) facility on existing brownfields site, while safely managing all subcontractors.