XL Concrete – Advanced Automated Water Treatment Facility By EES Electrics

XL Concrete, one of Victoria’s leading concrete suppliers, approached EES Electrics with a significant challenge: design and deliver a state-of-the-art automated water treatment facility that not only met strict environmental standards but also saved the company money by enabling the recycling and reuse of process water. From concept to commissioning, EES Electrics delivered a fully integrated, automated water treatment system that was tailored to XL Concrete’s unique operating environment and seamlessly tied into their existing plant.

The Challenge of Automated Water Treatment Facility Integration

Concrete plants generate massive volumes of wastewater through processes such as aggregate washing, slurry disposal, and equipment cleaning. At XL Concrete, this presented three major issues:

• Environmental Compliance: Wastewater with high pH levels and solids couldn’t be discharged directly, requiring treatment before release or reuse.

• Cost Burden: Sourcing fresh water daily was costly, especially during peak production.

• Manual Inefficiency: The old system relied on human oversight, leading to wasted labor and increased room for error.

XL Concrete needed a modern, automated water treatment system that would reduce costs, eliminate manual handling, and meet environmental obligations. EES Electrics provided the perfect solution with a fully automated, integrated system designed specifically to address these challenges.

Our Solution – A Fully Automated, Integrated Water Treatment System

EES Electrics designed, manufactured, and installed the complete automated water treatment facility, handling everything from control engineering to physical installation. Our work included:

1. Custom Control & Stainless Steel Enclosures Designed and built IP-rated stainless steel control enclosures capable of withstanding harsh concrete plant environments (dust, vibration, water exposure). We integrated PLC-based automation with timers, interlocks, and sensors, enabling the entire process to run without manual intervention.

2. Overhead Cable Tray & Supports Installed overhead cable tray systems with heavy-duty stainless supports to protect wiring from dust, water, and forklift traffic. This clean, elevated installation method ensured safety, reliability, and easy maintenance access.

3. Multi-Stage Water Treatment Tanks Engineered a multi-tank treatment process, including:

   • Primary Settling Tanks – Capturing slurry and allowing solids to separate naturally.

   • Secondary Storage Tanks – Equipped with stirrers to prevent sediment build-up.

   • Polishing Tanks – Fitted with molecule counters and chemical dosing pumps to neutralize pH levels and treat water before reuse.

4. Smart Pumping & Flow Control Installed multiple high-capacity pumps that automatically transfer water between tanks based on float switch levels. Pumps were interlocked with treatment stages to avoid overflow or dry running. Intelligent timers optimized pumping cycles, reducing energy costs.

5. Real-Time Monitoring & Safety Systems Installed flow meters and molecule counters to measure water quality at every stage. The control system was integrated with visual alarms and SMS alerts to notify staff if abnormalities occurred. This system linked to the plant’s main control network, offering live visibility into water quality and system status.

6. Integration with Existing Facility The system was designed to tie directly into XL Concrete’s batching plant and washdown systems, creating a closed-loop cycle. Treated water could be reused in mixing and washing, drastically reducing fresh water consumption.
   

The Outcome – A Smarter, More Sustainable Future

The new automated water treatment facility transformed XL Concrete’s operations in several key areas:

• Zero Manual Handling – The system operates automatically, freeing staff from constant supervision and reducing safety risks.

• Massive Water Savings – XL Concrete now reuses up to 80% of its process water, cutting water costs by thousands of dollars annually.

• Environmental Compliance – Water discharged from the system meets all environmental requirements, avoiding fines and protecting the company’s reputation.

• Seamless Operations – By integrating the system with the existing plant, there was no disruption to production during commissioning.

• Future-Ready – The modular design allows for easy expansion as the plant grows, ensuring the system remains scalable without requiring a complete redesign.
  

Conclusion – An Investment in Efficiency and Sustainability

At XL Concrete, water used to be a cost and a liability. Today, thanks to EES Electrics’ engineering and turnkey delivery, it’s an asset. We didn’t just provide electrical work — we provided a comprehensive solution that included:

• Engineering Design – A complete treatment process tailored to their site.

• Automation & Control – Seamless, hands-off operation.

• Integration – A system that works hand-in-hand with existing batching infrastructure.

• Cost Savings – Thousands saved annually through water reuse.

• Environmental Security – Compliance assured, reputation protected.
  

EES Electrics didn’t just build XL Concrete a water treatment facility — we built them a smarter, safer, and more sustainable future.