Mirani WRF Upgrade

Design, manufacture and delivery to site of concrete components required for construction


FLI Precast was approached by an Australian firm due to our proven track record using semi-precast systems successfully in water treatment facilities.


The approach included the first ever project in Australia to utilise a modular semi-precast system combined with a traditional in-situ design.


The solution created a water treatment facility capable of recycling and providing water for over 7,500 people in the surrounding areas.


UGL is a market leader in end-to-end asset solutions, delivering operational value and enhanced customer experiences through its whole-of-life offer for critical assets in power, water, resources, transport, defence and security, and social infrastructure. As a company UGL are striving to carry out more of-site manufacturing in keeping with the DfMA ethos.

UGL approached FLI Precast because of our proven track record in the UK and Irish water sectors to explore the opportunity of improving the delivery process whilst reducing site
programmes and preliminaries. This is the first project in Australia to utilise a modular
semi-precast system which is a traditional in-situ design, broken into individual pieces.

The elements are part of a 7,500 EP population wastewater recycling facility design and construction
project at Mirani in Queensland, which is a pilot installation undertaken with a view to exploring the application of FLI Precast’s semi-precast approach in Australia and South East Asia.

The 5.40m tall walls have been designed for a perfect fit in 20ft ISO containers at payloads of just under 25 tonnes each. The 625-tonne consignment fills 25 containers and will travel by sea through Dublin, Antwerp, Sydney and Brisbane, and then by road to Mirani.

The project catalysed several significant innovations, initially to facilitate containerisation but which will add value to routine operations across the FLI Precast
product range, both overseas and domestic.

Construction of the concrete structure is to commence early in September 2019 and will be installed on site in just three weeks – a significant time saving when compared to six weeks when using traditional methods.

A word from our client

We saw an engineering paper regarding the use of the semi-precast design and its advantages along with suppliers of various systems.

FLI Precast were recommended as the best in their field as their product had self-supporting legs and a lift frame system.

As a Project Manager, I have a philosophy to reduce the man hours worked on site and to do as much work of-site as possible.

This reduces the risk of injuring people on site, improves quality and reduces the impact of inclement weather.

The on-site programming benefits are also significant for our project because this enables us to progress multiple work fronts.

I was the General Manager of a precast manufacturer for 3 years. They precast bridge beams, culverts, retaining wall panels, etc. so I am
fully conversant with the advantages of using precast.

Australia has a precast industry. The industry includes: precast bridge beams, culverts, pits, pipes, tilt-up panels, noise walls, etc.

For water-retaining structures post-tensioned precast has been used in the past, but I am unaware of the semi-precast system being used before this project.

Project Overview

FLI Precast played a key role in utilising a modular semi-precast system to provide a water recycling facility in Queensland, Australia.

The was the first-ever project of its kind and illustrated how FLI Precast’s cutting-edge designs can be used across the globe.

Our logistics team was able to ensure the 625-tonne consignment of 25 containers traveled across different continents from Dublin to Antwerp and on to Sydney.

The team at FLI Precast was proud to be able to play a part in such a huge project.

Project Details

Location: Mirani, Queensland, Australia

Main Contractor: UGL Pty Limited

End Client: Mackay Regional Council

Services: Design, manufacture and delivery to
site of concrete components required
for construction

Start Date: August 2019

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