Process water systems, designed to manufacturing standards.
Potable and non-potable water lines, process water reticulation, plant feed lines, cooling water, and zone-isolated reticulation across copper, stainless steel, HDPE, PE and PEX. Installed to AS/NZS 3500 and your engineering spec, with backflow protection where the service crosses a hazard rating.
Four reasons engineering rings us.
Process water work usually starts with a deadline (new plant going in), a problem (failing reticulation), or a compliance flag (identification audit or backflow exposure). Here's the version we hear most.
New process line.
Engineering has a new piece of plant coming in and needs feed water (potable or otherwise) at a defined connection point by a target date. Pressure, flow rate and isolation already spec'd.
Failing reticulation.
Burst frequency on aged galvanised or AC pipe is rising. Each repair takes a line out, slows production, and the next one is a question of when not if. The line needs replacing, not patching.
Identification audit flagged.
Auditor or council has flagged unclear identification on existing non-potable or process water lines. Site needs lines tagged and identified per AS 1345 before sign-off.
Backflow exposure.
Sydney Water or council has advised the site needs zone or site-level backflow because a hazard rating applies. A boundary or zone backflow device is required to keep contamination off the drinking water network.
We do industrial water reticulation: potable, non-potable, process, cooling, and plant feed. Copper, stainless, HDPE, PE, PEX, PVC. Backflow installation, testing and certification where the hazard rating requires it. Specialist gas systems and trenchless renewal sit outside our scope. If the job crosses into one of those, we'll tell you straight on the site walk and refer to a specialist trade.
From a single plant feed to a full site ring main.
Most industrial water work falls into one of four scopes. Each has a different design, install footprint and certification path. Here's how we approach each one.
Potable water reticulation.
Site mains, internal ring mains, drinking water to amenities and food-grade tap points. Designed for pressure, flow and isolation, with backflow protection where the service crosses a hazard rating into a process zone.
We cover
- Site mains and ring mains
- Zone isolation valves
- Backflow install & testing
Worth flagging
- Disinfection required before handover
- Pressure test certificates issued
- Authority sign-off can add lead time
Non-potable & process water.
Recycled water, cooling water, washdown lines and process water reticulation. Clearly identified per AS 1345 with purple-lilac banding, flow-direction arrows and content labels, so there is no chance of cross-contamination with potable services.
We cover
- Recycled and cooling water lines
- Washdown reticulation
- Purple-lilac identification
Worth flagging
- Separation distance from potable
- Audit-ready labels on every drop
- Process temp may dictate material
Plant feed lines.
Dedicated water service to a specific piece of plant. Isolation at the takeoff, instrumentation tappings for pressure and flow, gauges where engineering wants visibility. Lockable isolation for shutdowns.
We cover
- Dedicated takeoff & isolation
- Gauge and instrument tappings
- Lock-out tag-out points
Worth flagging
- Plant commissioning window matters
- Flexible connections at the machine
- Vibration isolation if required
Reticulation upgrades.
Extending or re-zoning an existing reticulation network, replacing failed sections of aged steel or AC pipe, capping and isolating abandoned runs so they don't become a dead-leg or a corrosion risk to the live system.
We cover
- Network extension & re-zoning
- Failed section replacement
- Dead-leg capping & isolation
Worth flagging
- Old as-builts often missing detail
- Hidden services need locator survey
- Updated as-builts issued on completion
Industrial estates, mixed pipe vintages.
Wetherill Park, Smithfield, Eastern Creek, Penrith. The Western Sydney industrial corridor runs the gamut from 1970s galvanised mains through to modern HDPE drops put in last year. Most factory sites are working with what's there, not a greenfield install.
Our approach: survey what exists, mark up the live services properly, isolate before cutting, and replace into materials that will outlast the next reorganisation of the factory floor. We work around production, not over the top of it.
The accounts that prove it: Brickworks, Austral Bricks, Bowral Bricks, Austral Masonry, Yates Manufacturing (20+ years), Knauf Gypsum (15 years), Veolia Environmental Services (10 years), Penrith RSL Club. Long tenure on industrial reticulation is how this business runs.
What's under the slab on a typical Western Sydney site.
From drawing review to as-builts in your hands.
Industrial water work is paperwork as much as pipework. The order is the same on every site: review, induct, agree the materials, install in the agreed window, hand over certificates.
Site walk & drawings.
Walk the route, review existing as-builts (where they exist), identify hazard ratings on each zone, and assess the condition of any service we'll be tying into. Anything unclear gets flagged before we quote.
SWMS & induction.
Safe Work Method Statement and certificates of currency lodged ahead of the install date. Site induction completed for every operative attending. PPE matched to the site requirement.
Materials & isolation.
Confirm material selection (copper, stainless, HDPE, PE or PEX) against the engineering spec. Isolation strategy agreed with the site so production knows exactly what's down, when, and for how long.
Install & lock-out.
Install during the agreed window. Lock-out tag-out at every isolation. Pressure test on every new section, disinfection on potable lines per AS/NZS 3500. No live cuts on a process line without sign-off.
As-builts & certs.
Updated as-built drawings, pressure-test certificates and disinfection certificates handed over. 12-month workmanship warranty applies to the install. Invoice on agreed account terms.
Specified to the spec.
Material selection is half the install. We work across the standard industrial range and match the material to the duty: temperature, pressure, chemistry of the water and the access constraints of the route. Anything specialised (high-purity, food-grade stainless polish) is sourced through trade.
The questions engineering and facilities always ask.
Direct answers on standards, materials and certification. If your question isn't here, ring the workshop and we'll talk through it.
Can you work to AS/NZS 3500 and our internal engineering spec?
How do you identify non-potable and process water lines?
Do you provide pressure test and disinfection certificates?
What pipe materials do you carry and recommend?
Do you handle backflow where the service crosses a hazard rating?
Can you work in shutdowns or out of standard hours?
What's covered by the 12-month workmanship warranty?
Do you provide as-built drawings on completion?
Plant going in? Send the drawings.
Ring the workshop with the deadline, the duty and the connection points, or email the drawings and the engineering spec through. We'll come back with a route, material recommendation and a fixed quote on letterhead.