Managing water infrastructure for a major metropolitan region is a complex logistical challenge, especially when the service area encompasses 375 municipalities and more than 30 million people across the state of São Paulo, Brazil. For Sabesp, advancing a smart water transformation meant connecting people, processes, and technology to improve water and wastewater operations.
Sabesp, one of the world’s largest water and waste management companies, focuses on delivering safe, reliable services while protecting public health and the environment. The utility is currently working toward a major milestone: providing universal water and sanitation for the 30 million people in São Paulo. Meeting these goals in a rapidly changing environment requires looking beyond traditional infrastructure management approaches. For Sabesp, that meant updating its operational approach and fundamentally changing how it manages information by making the shift from fragmented, reactive processes to a proactive, data-driven framework, called INTEGRA 4.0. proactive, data-driven framework, called INTEGRA 4.0.
Breaking down siloed water utility data
São Paulo has a vast network of pipes, pumps, and treatment facilities; however, getting a clear, real-time picture of what was happening within that network was challenging. In early 2020, Sabesp conducted a comprehensive internal assessment. After analyzing over 80 digital tools, the team found that while Sabesp had plenty of data, it was heavily siloed. The volume of field data was simply too much for manual analysis, and resources were scattered across various local systems and manual controls.
One of the main challenges associated with disconnected data is slower decision-making. Teams are often forced to react to problems, such as pipe leaks, pressure drops, or sewage overflows, after they happen, rather than addressing these challenges proactively. For the communities that Sabesp serves, these issues resulted in low water pressure in vulnerable neighborhoods and instances where untreated wastewater entered local streams during system failures. To improve service reliability, Sabesp needed to break down these silos and transition from turning raw data into actionable insights.
Building water and wastewater digital twins
The INTEGRA 4.0 initiative is built on the idea that digital transformation requires not only the implementation of innovative digital solutions, but also a clear focus on people, processes, and technology. Sabesp turned to Bentley’s OpenFlows Water, OpenFlows Sewer, and OpenFlows WaterSight software to establish a connected hydraulic modeling environment. A key element of this approach is the development of a digital twin, a virtual replica of Sabesp’s physical water and wastewater networks. Sabesp integrated its geographic information system (GIS), commercial data, and field measurements into a single cloud-based environment. The digital twin allowed planners, engineers, and field operators to access the same information simultaneously. By centralizing the data, Sabesp created a single source of truth that improved collaboration and visibility across different departments.
Using real-time monitoring for proactive sewage management
Historically within the Brazilian water and wastewater sector, large-scale sewage collection networks were viewed as too complex to monitor in real-time, leading to the assumption that operational management would always remain reactive due to lack of integrated modeling and sensor technology. However, Sabesp is challenging this idea with its Sewage Operation 4.0 project, a first-of-its-kind initiative in Brazil.
In the densely populated Jardins area, which is home to 1.2 million residents, a large transient population, and major hospitals, Sabesp deployed Bentley’s OpenFlows Sewer and OpenFlows WaterSight to build real-time hydraulic models. By integrating these models with 90 maintenance hole level sensors that transmit data every five minutes, along with weather station forecasts, Sabesp developed a system that was able to anticipate failures.
This new technology also prompted a shift in workflows. Sabesp’s technicians transitioned into roles closer to data analysts, studying performance patterns and consumption profiles. Now, when system behavior deviates from the standard, an alert is triggered automatically. The results have been noticeable. Within seven months, Sabesp saw a 30% reduction in corrective services and sewage overflows in the targeted areas.
This proactive approach has a direct impact on the local environment. Previously, system limitations meant roughly 4,200 cubic meters of sewage could overflow into local rivers each month before repairs were made. Through these new initiatives, Sabesp is planning to intercept and treat an additional 1,400 liters of wastewater per second, which will keep 41 tons of biological oxygen demand out of the Tietê River daily.
Improving water supply efficiency
The digitalization approach also improved the water distribution side of the business. The Vicente de Carvalho district, an area with 150,000 residents and fluctuating seasonal tourism, frequently dealt with supply challenges like water shortages and low pressure. By implementing OpenFlows WaterSight, Sabesp gained better visibility into the network. The platform helped teams detect pressure anomalies, identify failing field equipment, and analyze water balances across different districts more efficiently. Instead of relying on manual spreadsheet analysis, staff could use the software to pinpoint issues.
Using this information, Sabesp optimized supply conditions, reducing apparent water losses in the studied area by 29%. Additionally, the system’s improved efficiency saved about 37,000 cubic meters of water per month, which helped stabilize water pressure and provide a more reliable supply for the district.
Measuring the impact of smart water operations
Ultimately, the success of any digital transformation is measured by its real-world return on investment. For Sabesp, launching the INTEGRA 4.0 initiative has modernized their workflows, improved operational efficiency and delivered significant savings. Using Bentley’s hydraulic modeling software significantly reduced diagnostic times. For example, evaluating the Parque Novo Mundo wastewater system would have historically taken about 1,200 hours using manual mapping methods. With OpenFlows Sewer, the evaluation was completed in just 140 hours, resulting in considerable time savings. Financially, the ability to simulate scenarios and target specific problem areas saved Sabesp approximately BRL 3.1 million in unnecessary works and corrective maintenance over a seven-month period. It also saved BRL 600,000 in customer claims related to sewage backflows and reduced fieldwork by 2,800 hours. Because maintenance is now more targeted, Sabesp is also able to reduce its operational CO2 emissions.
Advancing universal water and sanitation access
Reaching the goal of universal water and sanitation access for 30 million people is a long-term undertaking. As Sabesp continues to expand its INTEGRA 4.0 framework, the company is establishing more efficient operational standards and proving that this goal is within reach. By successfully integrating its data, processes, and technology, Sabesp is modernizing its services and working toward broader Sustainable Development Goals for clean water access and sanitation. Supported by a unified team and a clear digital view of its infrastructure, Sabesp has laid the groundwork to deliver safe, reliable, and sustainable water services to its communities for years to come.
Learn how Bentley’s OpenFlows helps water utilities build smarter, more resilient water and wastewater networks with connected hydraulic modeling, digital twins, and real-time operational insights.
