In wastewater treatment projects, one of the biggest cost drivers is new infrastructure. Tanks, civil works, and piling can quickly increase capital spend.
At Aerofloat, every project starts with a simple question. What already exists on site, and how can it be used more effectively?
By rethinking existing infrastructure, we helped one client reduce project costs by up to $400,000 while still delivering a high performing wastewater treatment system.
Starting with what is already on site
Rather than defaulting to new builds, Aerofloat begins by reviewing the assets already available.
On this site, that included:
- A large 15 megalitre pond collecting production wastewater and stormwater
- A second 5 megalitre pond
- An existing tank structure that had been in place for decades
Each of these assets presented an opportunity to reduce cost if they could be repurposed effectively.
Turning a pond into a balance tank
The first step was to transform the 15 megalitre pond into a functional part of the treatment process.
This pond was converted into a balance tank, or balance lagoon, by:
- Mixing and averaging incoming wastewater
- Using a brush aerator to maintain consistent conditions
- Managing flow variability before downstream treatment
Balancing wastewater in this way helps stabilise the overall system, improving performance across the treatment process.
Converting existing infrastructure into treatment stages
The second pond was repurposed into a nitrifying reactor.
This involved:
- Draining and desludging the pond
- Retaining the existing liner
- Installing pontoons and mooring systems
- Adding aeration equipment
Instead of building a new reactor, the existing structure was adapted to support biological treatment.
Reusing a legacy tank for the SBR
One of the most significant savings came from how the sequence batch reactor was designed.
An existing tank had been on site for over 50 years. This meant the ground beneath it had already been compacted and stabilised over time.
By designing the system around this location, Aerofloat was able to:
- Avoid installing deep structural piles
- Use the existing ground conditions to support the new reactor
- Reduce the need for extensive civil works
In many wastewater projects, piling can involve 30 metre deep supports and represents a major cost.
By working with the site conditions instead of against them, this cost was removed entirely.
Why this approach matters
Repurposing infrastructure is not just about cost savings. It also allows for:
- Faster project delivery
- Reduced construction complexity
- Lower environmental impact
- Better use of available space
For many industrial sites, this approach can unlock value that would otherwise be overlooked.
A smarter way to design wastewater systems
This project highlights the importance of flexible design thinking in modern wastewater treatment.
Rather than applying a standard solution, Aerofloat focused on:
- Understanding the site conditions
- Identifying opportunities within existing assets
- Designing a system that works with the infrastructure already in place
The result was a system that met performance requirements while significantly reducing capital investment.
Reducing cost without compromising performance
By repurposing ponds and existing structures, the final design delivered both efficiency and cost savings.
Avoiding piling alone reduced project costs by between $300,000 and $400,000.
These savings were passed directly to the client, without compromising system capability or long term performance.
Rethinking what is possible in wastewater treatment
In many cases, the most effective solution is not starting from scratch, but making better use of what already exists.
With the right design approach, existing assets can become key components of a modern wastewater treatment system.
For businesses looking to upgrade or expand, this can mean lower costs, faster delivery, and a more efficient outcome.
