Innovation and the continuous pursuit of sustainable solutions are at the core of Sacyr Water's DNA. A recent example is the successful completion of an underwater rehabilitation project at the Binningup Desalination Plant, located south of Perth, Australia. The project restored a key seawater intake asset without the need for full replacement, providing a cost-effective and sustainable alternative.
The intervention focused on the Transition Box, a concrete structure buried beneath the seabed that connects the intake pipelines to the plant's inlet tunnel. Following the identification of progressive structural deterioration and sand ingress into the system, an innovative engineering solution was developed to restore the asset's functionality and significantly extend its operational lifespan.
Engineering and Innovation Supporting Operational Excellence
To address this challenge, Sacyr Water worked closely with Water Corporation and a team of specialist engineering and marine operations partners to develop a solution with minimal environmental impact.
The resulting design incorporated a precision-engineered high-density polyethylene (HDPE) modular liner, reinforced at critical locations and sealed using purpose-designed injection systems to ensure long-term structural integrity and watertight performance.
Prior to installation, the solution underwent extensive validation through advanced Computational Fluid Dynamics (CFD) modelling, structural assessments and full-scale testing, ensuring its suitability for the demanding operating conditions of the marine environment.
Delivering a Complex Project in Challenging Conditions
The works were undertaken in a highly challenging setting, involving underwater operations, restricted access, narrow weather windows and stringent environmental requirements.
Specialist diving teams installed more than 75 custom-manufactured components within the existing structure, successfully restoring the integrity of the intake system while minimizing disturbance to the surrounding marine environment.
This innovative approach eliminated the need for full asset replacement, significantly reducing intervention on the seabed and minimizing operational disruption to a facility that plays a vital role in supplying drinking water to Western Australia.
Commitment to Sustainability and Asset Resilience
Operated by Sacyr Water, the Binningup Desalination Plant is recognized internationally for its commitment to innovation, operational excellence and sustainability. The facility supplies drinking water to a significant proportion of Western Australia's population and has earned industry recognition for its high environmental and operational standards.
The rehabilitation of the intake structure further demonstrates Sacyr Water's commitment to the efficient and sustainable management of water infrastructure assets. By applying innovative engineering solutions that extend asset life, optimize resources and reduce environmental impact, the company continues to strengthen the resilience and long-term performance of critical water infrastructure.
The project also received industry recognition within the Australian water sector, winning a 2025 marine infrastructure innovation award, highlighting the value of collaboration between engineering, operations and sustainability in addressing complex infrastructure challenges.
Through initiatives such as this, Sacyr Water continues to advance innovative solutions that enhance the resilience of water infrastructure and help ensure a safe, reliable and sustainable water supply for the communities it serves.