Progress on The New Wash Plant

Building a Custom Bruce Wash Plant at Thorncliffe Building Supplies

Work is progressing on the construction of a bespoke wash plant installation at Thorncliffe Building Supplies, where a fully integrated water processing system is being engineered to improve material quality and support efficient water management.

Designed and supplied with our partners Bruce Engineering, the project brings together advanced washing technology, sand classification and a full water clarification circuit within a single processing solution.

As with any major plant installation, the build is progressing in carefully planned stages. Here is how the project has developed so far.

Week 1 – Foundations of the Plant

26–30 January 2026

The project began with the arrival of the first major components of the wash plant. Structural elements including walkways, chassis legs and support frames were delivered to site, forming the foundation for the installation of the main washing equipment.

Shortly afterwards, the Bruce BWR arrived on site. Weighing approximately 28,000kg, the unit required a coordinated crane lift to safely unload and position the module along with its walkways and structural supports.

With the BWR successfully positioned, installation continued with the arrival of the pre-screen unit, delivered complete with its chassis, access steps and structural supports. The Bruce BWS was then delivered and installed, establishing the core washing and sand processing capability of the plant.

By the end of the first week, the main processing modules had been successfully positioned, marking a major milestone in the build.

Week 2 – Building the Flow of Material

2–6 February 2026

Once the core washing equipment had been installed, attention turned to the material handling infrastructure that will move processed material through the plant.

Several conveyors arrived on site, including 18-metre, 15-metre and 9-metre stockpile conveyors. A particularly notable addition was the delivery of a 38-metre lattice conveyor, which will play a central role in the plant’s stockpiling system.

This stage of the project also highlighted the level of custom engineering involved in the installation. Rather than using standard conveyor supports, bespoke swivel head supports have been designed allowing the conveyors to integrate seamlessly with the layout of the yard.

With conveyors staged near the plant ready for final assembly, the site began to take on the visual scale of the completed operation.

Week 3 – Connecting the Plant

9–16 February 2026

As more equipment arrived, installation teams began connecting the various systems that will allow the wash plant to operate as one integrated process.

Walkway assemblies were completed to provide safe access across the plant, while pipework was installed to connect the BWR and BWS units with the wider utilities system. Magnet belt systems and stainless steel covers were also fitted, alongside hydraulic connections for the hopper and tipping grid.

Stockpile conveyors were moved into their final positions and discharge chutes were installed, gradually forming the pathways through which processed material will move once the plant is operational.

During this phase, a 220-tonne crane mobilisation supported the installation of larger components and ensured precise placement of heavy structures. The plant was then drilled and bolted securely onto the concrete plinth foundations, anchoring the installation firmly in place.

Week 4 – Introducing the Water Management System

23–28 February 2026

With the primary processing infrastructure established, the focus shifted towards one of the most important aspects of the plant: water clarification and recycling.

Large structural components began arriving on site, including sections of the clarifier system and the lime silo that will support water treatment operations. These components form part of a closed-loop water system designed to clarify process water and allow it to be reused throughout the plant.

Assembly of the clarifier structure began shortly after delivery, while installation teams also began preparing the lime silo and associated equipment. At the same time, electrical installation work commenced, laying the groundwork for integrating the plant’s control systems.

This phase marks a key transition from structural installation to operational integration.

Week 5 – Sludge Handling and Filter Press Installation

2–6 March 2026

As the clarification system began to take shape, additional equipment arrived to support sludge management and water treatment.

The filter press housing was delivered and assembled. Alongside this, the vertical stocking tank and water drip tray were delivered and positioned on site.

These systems will ultimately work together to separate solids from the clarified water, allowing sludge to be dewatered efficiently while cleaned water is returned to the process.

During this stage, both the clarifier and lime silo structures were rotated into their operational positions, another complex task requiring careful coordination on site.

Week 6 – Major Lifts and System Assembly

9–13 March 2026

The project entered another significant phase as heavy lifting operations resumed. A 70-tonne crane was mobilised to support the assembly of the clarifier system and the positioning of key water treatment components.

Additional clarification plant containers, electrical control panels and accessories were delivered to site and integrated into the growing system. The filter press housing continued to be assembled, bringing the sludge handling infrastructure closer to completion.

Shortly afterwards, a 150-tonne crane was brought in to carry out several precision lifts, turning and positioning of the clarifier, vertical stocking tank and using the telehandler to adjust the lime silo.

These lifts allowed the final structural elements of the water treatment circuit to be installed.

Current Phase – Final Integration

Work is now focused on completing the final assembly of the clarification plant and integrating the remaining systems across the installation.

Current activities include the assembly of clarification plant accessories, installation of piping throughout the water treatment circuit, and electrical integration of the plant’s control systems.

As these systems come together, the wash plant moves closer to commissioning – when all equipment will be tested, calibrated and prepared for full operation.

A Plant Taking Shape

What began as a series of equipment deliveries has rapidly developed into a fully structured processing installation.

With the main wash plant equipment now in place and the water clarification systems being assembled, the site is entering the final stages of construction.

Over the coming weeks, electrical integration and system commissioning will bring the entire operation online, completing a highly engineered wash plant designed to deliver reliable, efficient material processing for years to come.