Delivering resilient water treatment with stainless steel
Stainless steel is fast becoming the material of choice across new and upgraded water infrastructure projects in Australia, valued for its durability, corrosion resistance, and long-term sustainability. This shift was on full display in the Gisborne Recycled Water Plant Upgrade in Victoria, where ASSDA Member and Accredited Fabricator, Total Piping & Mechanical (TPM), delivered expertise that strengthened best practice for stainless steel use in recycled water treatment facilities.
Installed in September 2024, the stainless steel pipework forms a key component of Greater Western Water’s wider upgrade of the Gisborne Recycled Water Plant. The overall project will increase treatment capacity and improve operational efficiency to support the growing Gisborne and New Gisborne communities. The upgrade featured new inlet works with advanced screening and grit removal, a biological nutrient removal (BNR) bioreactor, and the integration of a state-of-the-art four-membrane-tank system (MBR) to meet stringent environmental standards.
At the heart of this delivery was stainless steel. TPM fabricated and installed 12,500m (31.5 tonnes) of 316L stainless steel pipe alongside significant plate fabrication for various components. All pipe was supplied in schedule 10 mill finish and fully passivated by way of passivation bath upon completion, ensuring maximum corrosion resistance and performance in the demanding wastewater treatment environment.
Stainless steel was the material of choice, which was supplied by ASSDA Member Midway Metals, for the Gisborne upgrade due to its exceptional corrosion resistance, durability, and hygiene properties. In wastewater environments, 316L stainless steel resists pitting corrosion, while its smooth surface limits biofilm formation, supporting stringent water quality standards. Its strength and versatility enabled TPM to fabricate complex piping systems, high-pressure components, and precision elements. Beyond technical performance, stainless steel contributes to sustainability, being fully recyclable, energy-efficient and low maintenance – ensuring the upgraded plant delivers long-term operational reliability and reduced lifecycle costs.
TPM’s scope included aeration pipework with fine bubble diffusers, installation of seven new blowers for membrane scouring, sludge handling equipment, advanced chemical dosing systems, a UV treatment system, and odour control units. Each element demanded precision fabrication, integration, and rigorous quality assurance to guarantee the reliability of the upgraded facility.
The project also highlighted TPM’s strength in project management. Its flange management methodology and stringent Quality Management System ensured the integrity of every connection and compliance with Australian standards and has led to TPM achieving ISO 9001 Accreditation. A staged installation approach allowed work to progress without disrupting live plant operations, a critical achievement in maintaining compliance with discharge license requirements.
The use of stainless steel was not just about meeting today’s demands – it was about safeguarding the plant’s future. From energy-efficient aeration systems using stainless steel diffusers to robust mechanical components designed for decades of service, TPM’s fabrication expertise has provided Greater Western Water and the community with infrastructure that is both sustainable and resilient. These upgrades have also improved energy efficiency across the plant, reducing operational costs and supporting long-term environmental sustainability, while maintaining high water quality standards.
For its outstanding contribution, TPM was recognised for this project with the 2024 Australian Industry Stainless Steel Fabricator Award in the Process Industries category, affirming its leadership in stainless steel fabrication for critical infrastructure.
The Gisborne Recycled Water Plant Upgrade demonstrates how stainless steel is shaping the future of Australia’s water sector. With projects like this, stainless steel continues to prove its worth as the backbone of sustainable and resilient infrastructure – delivering durability, environmental performance, and long-term value for communities nationwide.
Aerial photo courtesy of Greater Western Water.
This article was featured in Australian Stainless Magazine 83.
