How Pipe Management Australia and Smart Lock created efficiencies and delivered an outstanding result in project delivery.
Pipe Management Australia (PMA), in partnership with Moody Civil & Pipe and Smart Lock Group, has delivered a challenging rehabilitation project for Unitywater’s Redcliffe Sewage Treatment Plant (STP) outfall line. The works demonstrated how Smart Lock’s stainless-steel sleeve system provides a fast, durable, and low-disruption solution for structural joint repairs in large-diameter pipelines.
Responding to a Critical Asset Challenge
In the aftermath of former Tropical Cyclone Alfred, Unitywater identified signs of potential leakage and joint failure along a DN950 vitrified clay (VC) outfall line connected to the Redcliffe STP. The pipeline is a vital piece of infrastructure, carrying treated effluent from the treatment plant to the outfall under continuous operation.
Given the importance of the asset, any investigation or repair required an approach that would maintain service continuity and environmental compliance throughout the project and deliver a long-lasting, structural solution.
Unitywater engaged Pipe Management Australia to deliver an end-to-end rehabilitation, from inspection and condition assessment through to structural repair and relining. The goal was to restore the asset’s integrity quickly and safely, without disrupting plant operations.
From Condition Assessment to Design
PMA began with a live-flow inspection using its in-house RACER™ technology to gather condition data and confirm the source of infiltration. The inspection was completed in a single night shift and provided the information needed to plan a targeted rehabilitation.
The findings revealed multiple leaking joints and signs of structural degradation. Based on this, PMA recommended a staged trenchless solution incorporating Smart Lock sectional repairs to restore the joints, followed by spiral-wound PVC lining for long-term structural renewal.
To prepare for installation of the Smart Lock repairs, PMA and Moody Civil & Pipe implemented a 2.6-kilometre bypass system to enable access to the asset while the repairs were completed.
Smart Lock: A Structural Solution for Live Systems
At the heart of the Redcliffe rehabilitation was Smart Lock, a stainless-steel sleeve system with a resin-impregnated liner that bonds the sleeve to the host pipe upon installation.
The mechanical expansion of the sleeve presses the liner firmly into the pipe wall, sealing infiltration and restoring joint strength.
Unlike conventional patching technologies, which require long curing times and limit productivity, Smart Lock allows multiple repairs to be completed in quick succession. The resin cures in place behind the stainless-steel sleeve, enabling crews to move immediately to the next repair, significantly reducing overall project time.
For the Redcliffe outfall, PMA installed 74 Smart Lock repairs within the DN950 line, each under live-flow conditions. The installation of each sleeve took only minutes, providing immediate structural reinforcement and watertight sealing.
This approach was particularly well-suited to the project’s requirements, allowing rehabilitation to proceed safely, efficiently, and without costly excavation or extended bypass operations.
“Smart Lock’s design gave us the speed and confidence we needed to rehabilitate the outfall under continuous flow,” said Justin Johansen, CEO and Director of Pipe Management Australia. “We were able to complete dozens of sectional repairs without waiting for individual patches to cure, and each one delivered a long-lasting, watertight seal.”
The Smart Lock portion of the project involved seven PMA team members, supported by Smart Lock and Moody Civil & Pipe personnel and was completed in two days.
Integration with Broader Rehabilitation
The earlier Smart Lock installations played a critical role in stabilising the host pipe, preventing further infiltration and providing a reliable substrate for relining.
Over 367 metres of DN950 pipeline were subsequently relined, extending the service life of the asset and delivering a fully sealed system from joint to joint.
Throughout the process, PMA’s teams maintained full operational control, ensuring the project was delivered on time, within Unitywater’s budget, and with zero disruption to the treatment plant’s operations.
Benefits of the Smart Lock Approach
By integrating Smart Lock into the rehabilitation design, PMA achieved significant time, cost, and safety benefits:
- Rapid Installation: Each Smart Lock sleeve was installed in minutes, with no need to wait for curing between repairs.
- Structural Strength: The stainless-steel sleeve and resin liner combination restored joint integrity and eliminated infiltration.
- Live-Flow Capability: Installation under full flow conditions avoided costly shutdowns or large-scale bypass pumping during repair works.
- Safety and Efficiency: Reduced confined-space entries, less heavy plant movement, and minimal site disturbance improved safety outcomes.
- Long-Term Value: The system provides a permanent, corrosion-resistant solution that supports future lining or relining works.
For Unitywater, this approach offered a proven and repeatable model for addressing similar challenges across its network.
“This project demonstrated how Smart Lock can deliver structural repairs quickly and safely in high-risk environments,” Johansen added. “It’s a technology that brings measurable value not only to utilities but also to their contractors, by streamlining delivery without compromising quality.”
Collaboration and Innovation
The success of the Redcliffe project was built on strong collaboration between PMA, Unitywater, Moody Civil & Pipe, and Smart Lock Group. Each partner contributed technical expertise to ensure the works were completed safely, efficiently, and to the highest standard.
The integration of Smart Lock within PMA’s full-service trenchless delivery model, encompassing inspection, design, bypass management, repair, and relining, exemplifies how modern trenchless solutions can address complex infrastructure challenges.
A Benchmark for Future Works
Unitywater’s Redcliffe Outfall project stands as a clear example of how mechanical point repair systems like Smart Lock can be deployed to deliver rapid, durable results. 
By combining accurate condition assessment, targeted sectional repairs, and comprehensive relining, PMA provided Unitywater with a fully rehabilitated pipeline, all completed under live-flow conditions and without interruption to operations.
The outcome is a strengthened, watertight system that will serve reliably for decades to come, setting a new benchmark for trenchless rehabilitation across Australia’s wastewater networks.
Learn more about Pipe Management Australia's full suite of rehabilitation solutions.
