Teesside Biomass
Client: BWV
Main Contractor: BWV / Lagan
Sector: Power Generation
Steel: 2,500 te
Completed: 2016 – 2019
Location: Teesside
Scope: Structural Steelwork
  Roof trusses
  Plate girders
  Steel doors
  Composite cladding
Metalwork Ancillaries
  Open grating
  Chequer plate
Services: Detailing
Connection Design
Site Installation

Project Background

Located in a coastal environment at Port Clarence, north of the River Tees, the 40Mw Renewable Energy Plant was designed to accept 100% waste wood fuel and to supply heat to the adjacent site.

The site was approximately 5.33ha of brownfield land previously used in a number of heavy industrial processes.

Our extensive scope included all primary and secondary steelwork, ductwork, and cladding, to form all structures on the site: 

Boiler House support structure: including galleries and air ducts, with approximate footprint of 1,072m2;

Boiler House secondary frame: fully clad, 40 metres high;

Turbine Hall: fully clad, 21 metres high with approximate footprint of 500m2;

Workshop: fully clad, 12 metres high with approximate footprint of 530m2;

Fuel Store: fully clad, 22.5 metres high with approximate footprint of 1,712m2;

Flue Gas Treatment (FGT) Stack: fully clad, 23.5 metres high. 

Supply and Fabrication

Our inhouse project team managed our fabrication of all structural steelwork, including cruciform columns, plate girders, and gallery platforms to form the primary Boiler structure The primary boiler frame design was formed of European section sizes, and fabricated using weld procedure 136.

We also prefabricated two trusses for the Workshop building, approximately 15.5 metres long by 2.5 metre deep and each weighing in-excess of 15 tonnes.

The Fuel Store comprised of thirty Category C columns each weighing up to 8 tonnes, which supported a portal frame spanning 27 metres with Category C runway beams.

Our project team coordinated the deliveries for all steelwork to be hot dip galvanised at our subcontractor’s facility.

We also supplied and installed all of the ancillary items required to form the structures, which included over 1,080 square metres of Kingspan MD80 metal decking, more than 2,000 square metres of open grid flooring, 600 square metres of durbar plate flooring, more than 4,250 linear metres of handrail, and 860 open grid stair treads.

Site Installation

We erected the steelwork in various stages dependent on the type and size of plant and equipment to be installed in each individual building.

A high level of co-ordination was required between the steelwork, metalwork ancillaries, cladding, and ducting install.

Our team managed primary hazards such as working at height and heavy lifting, with site managers ensuring communication of risk assessments, method statements, and tool box talks with the workforce. Communication was also via inductions, safety briefings, site notices, etc., while our Site and HSE managers attended monthly safety board meetings.

Following installation of the large process equipment, we installed the secondary steelwork and cladding to form the individual building envelopes.