Modules were preassembled off-site under controlled conditions to minimise risk of in-tank damage. All stainless steel supports and AccuGrid panels were precision-cut in Hayes’ workshop.

A just-in-time delivery strategy ensured safe unloading and movement of modules into tanks using internal rigging systems. Specialised walkways were constructed using plywood and grating to protect the delicate surfaces during install.

Due to restricted working access and the scale of each tank, all six tube settlers were installed sequentially using a phased approach. Each unit was hoisted into position, seated on laser-leveled stainless supports, and trimmed in place as per manufacturer’s drawings.

Brentwood’s engineer was consulted for layout verification and tolerance inspection before final fixing.

Hayes Mechanical applied precision survey tools and digital level systems to achieve the +/- 1/8” flatness tolerance across each tank. Bespoke handling trolleys and non-abrasive transport tracks were designed in-house to reduce physical strain and module damage.

All works were completed under tight environmental controls due to the project’s critical water treatment nature. A project-specific RAMS was developed in conjunction with Veolia, ensuring strict safety for confined space access, lifting, and manual handling.

No waste chemical processing was required, and off-cuts of PVC were segregated and recycled per supplier guidelines.

The Lough Mask Water Treatment Plant project represents the highest standards of precision, innovation, and environmental responsibility in the field of mechanical installation and stainless steel fabrication.

Delivered by Hayes Mechanical & Engineering, the project involved the challenging mechanical installation of six large-scale stainless steel tube settler systems at a critical national water facility in Tourmakeady, County Mayo. These IFR6000 modules, designed by Brentwood Industries (USA), are key to the plant’s water clarification process and required an extraordinary level of accuracy, care, and coordination to install within the confined geometry of deep settlement tanks.

This was not a standard steel job. Each 27-metre-long settler was preassembled off-site, rigged into position within millimetre tolerances, and secured onto precision-engineered stainless supports fabricated by Hayes. A bespoke handling solution was developed to protect the fragile PVC media during placement, while in-tank grating (AccuGrid) was laser- cut and installed under strict quality controls.

Stainless hardware, custom fixings, and fabricated walkways all contributed to a robust and hygienic installation—essential for potable water infrastructure.

The complexity of working within water tanks demanded advanced safety planning, including confined space protocols and a fully engineered RAMS developed with the client, Veolia Water Ireland. Despite access limitations and delicate components, the Hayes team executed the works flawlessly and ahead of schedule, without rework or waste.

This project is a model of efficient, prefabrication-led mechanical construction. All stainless steel elements were produced in Hayes’s own facility, ensuring consistency, safety, and sustainability. Every off-cut was accounted for, and the project generated no chemical or hazardous waste.