Milestone Services successfully delivered a complex upgrade to Environex’s sulphuric acid handling infrastructure at their live production facility. Executed without disrupting ongoing operations, this high-risk project showcased our expertise in hazardous environments, regulatory compliance, and innovative engineering solutions.

Project Scope

• Reconstruction of chemically-resistant bunds with enhanced containment capacity.
• Refurbishment and compliance upgrades to existing tank infrastructure.
• Design and installation of a PLC-controlled automated pump system with fail-safe features and remote monitoring.
• Construction of a fully compliant truck unloading bay with spill containment and recovery systems.
• Safe cleaning, neutralisation, and decommissioning of legacy systems.
• Implementation of simplified pipework, maintenance walkways, and modular designs for future scalability.

Key Challenges & Solutions Operating in a live chemical plant with no existing design documentation required meticulous planning. Milestone conducted a comprehensive site investigation, reverse-engineering system layouts to develop a safe, compliant construction methodology. Our team managed the safe handling and disposal of residual sulphuric acid, adhering to Western Australia’s Dangerous Goods Safety legislation and EPA environmental standards.

The new truck unloading bay was designed to meet DMIRS regulations, featuring a dedicated sump system and dual-drain infrastructure to manage chemical spills and rainwater separately. Temporary containment measures and precise scheduling ensured Environex’s production remained uninterrupted throughout the project.

Outcomes

• Enhanced safety and operational efficiency through automation and modern infrastructure.
• Full compliance with DMIRS, EPA, and Australian Standards for chemical storage and handling.
• Long-term maintainability with accessible, modular designs.
• Zero production downtime, achieved through close collaboration with Environex staff.

This project underscores Milestone Services’ ability to deliver multi-disciplinary upgrades in challenging environments, prioritizing safety, compliance, and client operations