Costain has been selected by Severn Trent to deliver major upgrades at Rugby Newbold Sewage Treatment Works, using off-site manufacturing and design for manufacture and assembly to drive programme efficiencies and enhance safety.

Acting as both principal contractor and principal designer, Costain will design and construct a new activated sludge plant to strengthen resilience and increase the site’s capability to treat dry weather flow. The biological treatment facility, which uses microorganisms to break down organic pollutants, will be integrated with existing systems and lift overall capacity by 28%, from 21,600 m3/d to 27,598 m3/d, by 2028.

The added capacity is intended to ensure compliance with AMP8 WINEP requirements for higher dry weather flow permits, improving operational resilience during periods of changeable weather.

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The scope also includes new pumping stations, four final settlement tanks each 29 metres in diameter, and a chemical dosing plant. In addition, Costain will expand and upgrade the inlet works, increase feed and storm capacity, and deliver improvements across various facilities and utilities. This element will be undertaken collaboratively with Severn Trent to de-risk any potential risks at the inlet.

The programme, valued at approximately £45m, runs until 2028. Costain will apply its Production Thinking approach, combining modern methods of construction, including off-site manufacturing (OSM) and design for manufacture and assembly (DfMA), with new technologies to identify efficiencies across delivery.

Matt Bateman, Water Sector Director at Costain, said: "We have a long-term trusted partner relationship with Severn Trent and are looking forward to once again having the opportunity to deliver high quality infrastructure upgrades quickly and safely. This award is built on our excellent track record of identifying construction efficiencies and delivering best-in-class solutions that maximise value for Severn Trent and its customers."