Solids-flux theory (SFT) and state-point analysis (SPA) are used for the design, operation and control of secondary settling tanks (SSTs). The objectives of this study were to assess uncertainties, propagating from flow and solids loading boundary conditions as well as compression settling behaviour to the calculation of the limiting flux (J_L) and the limiting solids concentration (X_L). The interpreted computational fluid dynamics (iCFD) simulation model was used to predict one-dimensional local concentrations and limiting solids fluxes as a function of loading and design boundary conditions. A two-level fractional factorial design of experiments was used to infer the relative significance of factors unaccounted for in conventional SPA. To move away from using semi-arbitrary safety factors, a systematic approach was proposed to calculate the maximum SST capacity by employing a factor of 23% and a regression meta-model to correct values of J_L and X_L, respectively – critical for abating hydraulic effects under wet-weather flow conditions.