Anchorsholme Park Case Study

Project Description

Project: Design and Build, New Build
Client: C2V+ and United Utilities
Contract Responsibilities: Main Contractor
Contract: NCE 3
Project Value: £2.7 million
Programme: Sept 2017 to Jan 2019

The Overview

A design and build project consisting of the full construction of four buildings for United Utilities and Blackpool Borough Council in an £80miillion redevelopment of Anchorsholme Park, Fylde Coast, Lancashire, in this project which is set to improve the bathing waters in and around the Blackpool Coastline.

The site consisted initially of parkland and a small bowling club which was to be demolished and reconstructed to a higher specification,

including a split usage building for the bowling club itself, and the local authority maintenance store and mess for the park maintenance teams. A new café and amphitheatre was also constructed for the local residents to enjoy, along with sports pitches and facilities and an outside adventure playground. The final parts of the development consisted of an operations and electrical MCC building and a large control building over a 40m deep stormwater detention tank.

The existing water treatment works at Fleetwood WTW had no additional spare capacity and therefore Anchorsholme Park was development to include a new detention tank and outfall under the proposed new seawall and promenade for storm water disbursal.

The Challenge

There were a number of key stakeholders concerned with the project from the Principle Contractor of C2V+ to the local authority, Bowling Club members and United Utilities themselves. The design of the ground works and substructure to three of the buildings was undertaken by Gallaway, with ground condition considerations through variable mediums. All buildings consisted of steel frames with suitable steel finishes through specification, and the coastal location of the site itself presented a number of challenges with high wind loads on all structures. Client interface on the performance specifications and end user requirements were ongoing throughout the course of the project.  Materials challenges and the selection of client proposed materials added challenge to the build process to ensure the scheme became workable.

The project can take pride on the improvement it makes to the environment with ecological and natural conservation, water quality improvements, hydrology and flood mitigation

The Solution

Gallaway have been involved at all stages of the design and build programme to co-ordinate between the client, Gallaway designers, statutory authorities, suppliers and other stakeholders. Weekly collaboration and planning meetings ensured overlap between the Gallaway works and those of the client and their own direct specialist trades were coordinated from a Health and Safety viewpoint whilst ensuring environmental and quality compliances were maintained at the highest levels  and ensure programme delivery on this marquis project.

Unit Fit-out Frontier Park Blackburn

Project Description

Project: Frontier Park Blackburn
Client: Taziker
Contract Responsibilities: Cast new pad foundations for client-installed steelwork and overhead traversing cranes. Office fit-out, including new stud walls to form office space, canteen, toilets, and storage rooms.
Contract: NCE 3 Option A
Project Value: £285,000
Programme: December 2022 to March 2023

The Overview

Our clients newly accuired unit required fitting out to accommodate their expanding business. Gallaway Construction were employed to break out pockets in the existing slab, excavate and cast new pad foundations to allow the client to install their steelwork and overhead cranes. We also expanded the exisiting office space to include new open plan and private offices, a large canteen with fitted kitchen, toilets with IPS cubicles, drying room and segregated store room for plant and materials. This included new drainage connections, upgrading the water and heating supplies, all decorated and finished to a very high standard.

The Challenge

The client had a very tight schedule to move from their existing facility, install the new steel and cranes and ensure minimum downtime in their production, along with coordinating site activities around the clients works.

The Solution

Gallaway’s thorough planning and diligent workforce were able to work around the client’s extraordinary requirements, working longer days and weekends to ensure no unnecessary loss of the client’s production time. The professionalism of Gallaway’s staff from Management to subcontractors has resulted a very pleased client and repeat business at various locations around the UK.

Home Bargains Refurbishments

Project Description

Project: Alfreton Store
Client: Home Bargains & Richard Jackson Ltd
Contract: Bespoke agreement
Project Value: £256,000
Programme: 12 weeks

The Overview

Our regular client has an existing store building in the town centre of Alfreton, Derbyshire which has had problems with water ingress from the car park which sits on top of the building. The ingress was beginning to affect the store building below. The consideration initially was to provide a new waterproof deck to form a new reusable car park on top of the store building. However, later the client decided to utilize the car park with a new covering to form a roof over the store.

The Challenge

The store needed to remain fully operational during this complex project. Therefore, solutions are needed to work around store opening and delivery hours and with particular regard to staff and members of the general public through our work interfaces. Also, to accommodate continuing deliveries in retaining access and ramps.

Using their knowledge of the performance requirements, Gallaway shortlisted from their extensive supply chain several technical departments from roof membrane and painting system providers list to discuss the technical challenges of the bespoke project. Gallaway offered several specifications and cost options to the client to obtain the best value.

The Solution

The final scope provided the most workable solution offering the best value and long-term warranties. The works considered the removal of existing car park deck finishes, replacing drainage including a new drainage system for surface water and various concrete repairs throughout. Gallaway worked shift patterns and introduced dual supervision during the day, evening, and weekends to ensure the store remained watertight at all stages of the works.

INX International Building

INX International Case Study

Project Description

Project: Remedial Mezzanine Floor Works
Client: INX International
Contract Responsibilities: Main Contractor
Contract: JCT Intermediate Works
Project Value: £124,724
Programme: May to June 2020 (During COVID-19 Pandemic)

The Overview

INX International are an American-based company producing inks for the food packaging sector. Their recently constructed warehouse was built to satisfy a desire to expand business in the beer and beverage can markets throughout Europe and the Middle East. It features the most efficient ink-producing equipment for two-piece metal decorating inks.

The new building was constructed to enable INX to install more state-of-the-art equipment dedicated to producing certain colours and provide greater efficiencies regarding production up time and waste elimination. There was a flaw within the construction of the original building in that a mezzanine floor was defective and not specification compliant. As the previous contractor had entered administration, Gallaway was appointed as contractor to undertake reactive remediation of the previous defects, which took place promptly within 3 weeks from the order agreement to commencement of the works on site. Gallaway was appointed to bring the facility up to specification with a fire rating and structural provisions to ensure insurance compliance and enable the facility to operate at increased capacity during the Covid crisis.

After the original contracted works and midway through the original contract period, Gallaway was appointed to undertake additional work to extend the external service yard to offer increased storage capacity for raw materials to enable INX to fulfil increased requirements.

The Challenge

The building consisted of a highly explosive and dust-free environment within the areas of working. Therefore effective temporary screening and ventilation requirements were critical to ensuring the works could take place without environmental contamination risk and to ensure the health and safety requirements were achieved. The works further took place over the existing office spaces, with necessary breaking out of existing mezzanine screed flooring giving rise to potential debris falling into the office ceiling space below or worse, into the offices themselves, and potential damage to the existing precast concrete floor units through the breaking out process.

Added complication existed in that the new structural concrete deck could not contain a damp-proof separation layer between the proposed new slab and the existing precast concrete units, and the risk of water seepage upon installation of the new concreting was possible. Different shift patterns and health and safety considerations, particularly noise and dust, for the existing workforce and the end user product needed to be eliminated. Mitigation of disruption to the business, enabling their shift patterns to continue, limiting disruption, and separating the office workers/limitations of car parking from the construction workers and construction disruption were key to the successful delivery of the project.

The Solution

As Principle Contractor, Gallaway instigated a series of mitigation procedures to overcome the effects of the disruptive nature of the construction works. Gallaway and INX discussed the critical working times within the existing factory, peak working times for staff attendance, and car parking provisions. Further discussions took place around client delivery schedules, vehicular movements, the client-required storage areas and access provisions. The result was Gallaway managed external areas suitable for a dedicated site compound, materials storage bays and external building access for the works. The key importance was for Gallaway operatives to remain separated from the INX workforce with consideration to limit interface and interruption to the INX production but put Covid control measures in place. Gallaway provided site layout plans, exclusion areas, temperature checks, separate welfare provisions, and additional PPE such as face fit masks, handwashing provisions, etc.

The agreement was made to penetrate the external first-floor wall of the building via the removal of external cladding and steelwork to provide their isolated site compound and access provision. Temporary scaffolding and access staircases were installed externally to separate construction movements from the factory, warehouse and offices. In addition, Gallaway installed temporary screening measures around the works area to eliminate dust and introduced positive ventilation pressures to extract construction dust from the building. Night shift and weekend working were utilised to separate the construction works from the peak operations of the factory and warehouse. In adopting night-time working procedures, Gallaway ensured through collaboration with the client that out-of-hours call inspections and dedicated client liaison were in place in the event of necessary hold point inspections. Equally, Gallaway ensured senior members of management were on call to resolve any necessary factors during all night-time working.

Gallaway utilised inspection test plans and records as standard by all projects. However, on this project, Gallaway introduced additional hold points and checking procedures to ensure dust, vibration and noise pollution were monitored regularly as early indicators of potential problems, allowing additional measures if required. Risk assessments and method statements, as standard, consider plant and equipment which limit dust, noise and vibration to a minimum to protect the environment of all stakeholders but to limit welfare/health and safety exposures of workers to HAVS, dust inhalation, noise and general personal protection.

INX Warehouse Space
INX International Building
INX Work In Progress
Cog Moors Picture

Cog Moors WwWT Case Study

Project Description

Project: Cog Moors WwTW, Pre and Post THP Buildings
Client: Skanska and Welsh Water
Contract Responsibilities: Design & Build Steelwork, Cladding, Mezzanine Floor, Fit Out
Contract: NEC3
Project Value: £850,000
Programme: 20 Weeks

The Overview

Cog Moors WwTW is a wastewater treatment works between Barry and Dinas Powys in South Wales to serve the residents of Dinas Powys, Sully, Penarth, Barry and the West of Cardiff, and which was first opened in 1990.

Welsh Water invested over £50 million to install an Advanced Anaerobic Digestion (AAD) plant as part of an overall upgrade to the treatment works on the site. As one of the largest energy users in Wales, Welsh Water had looked at ways of generating electricity on their sites to lower their costs in maintaining a network of sewers, sewage treatment works and reservoirs to become an energy-neutral business. To achieve this, further investment is needed in AAD, solar, hydro, wind and other renewable technologies.

The Cog Moors AAD site will assist Welsh Water in meeting its 100gGWh production of electrical, renewable energy target for 2020. In addition, the AAD plant will enable the Cog Moors Wastewater treatment site to work self-sufficiently and become a carbon-neutral site. The new AAD facility will also enable more green (bio) gas to be recovered from the waste.

The Challenge

Gallaway was contracted to complete these two buildings’ designs, including fire protection to external cladding and intumescent painting to steelwork. The design and coordination of fire-stopping details around service penetrations were required to offer a suitable building performance for the end usage. Quality and environmental considerations were high on the project, and the necessity for off-site application of fire protective coatings was considered to limit environmental impact.

Following consultation, the decision was made to treat the steelwork on site to mitigate the risk of damage to painted surfaces through transportation and lifting of the steelwork. Therefore leading to better quality but providing environmental considerations which needed to be overcome. In addition, screening, masking and ventilation were introduced to nullify the implications of site painting applications.

The Solution

Further challenges were provided midway through the contract when the Covid-19 pandemic occurred. Gallaway engaged closely with our client through the Covid-19 period of lockdown and worked as key workers to ensure the building was handed over with minimal delays caused by the pandemic. Following the lockdown, Gallaway implemented detailed amended Risk Assessments and methods of working over two weeks. The works were ready to remobilise in full accordance with the Government Guidelines. They were awaiting confirmation of acceptance of the RAMS from our client and letters confirming key worker status. Gallaway recommenced the works three weeks after the lockdown, fully following the new requirements through legislation.

Cog Moors Picture
Cog Moors Picture 2
Carrington Power Car Park

Carrington Power Car Park

Project Description

Project: Drainage and Service Enabling Works, Public Access Formation and Security Works.
Client: ESB Ireland.
Contract Responsibilities: Principal Contractor.
Contract: Client Bespoke Contract.
Contract Value: £130,000.
Programme: June 2018 for 8 Weeks.

The Overview

Carrington Power Station is a Combined Cycle Gas Turbine power station completed in Autumn 2016 and began commercial operation on 18 September 2016.

It is located on the site of a former coal-fired power station, close to the villages of Carrington and Partington in the Greater Manchester Area and 12 km southwest of Manchester City Centre. The Manchester Ship Canal and the River Mersey run alongside the site. Because the station’s site was surrounded by water on two sides, its strata were variable, so all of the buildings’ foundations were piled.

Approximately 7,850 piles were made, all of the reinforced concrete construction, with an average length of 30 feet (9.1 m) and a load of 50 tonnes per pile also due to the original Barton Power Station ground of high-risk asbestos in various areas.

The new station was constructed for £500 million and can generate 884MW of electricity (at a 58% efficiency rate); enough power to supply a million homes. Irish utility company ESB Group purchased an 85% stake in the project from Carlton Power in September 2008. The station is also a combined heat and power plant, capable of providing nearby businesses with steam if they require a supply.

Gallaway Construction Limited was contracted as Principle Contractor to ESB Group to design, manage and construct a new car park, footpaths and fencelines to an area within the existing power station site to provide the contractor with visitor parking. The contaminated land area, including asbestos-based materials, required necessary surveys and remediation as part of the construction works following the provision of the Pre-Construction and Construction Phase Health and Safety Plans.

The Challenge

Working on a live power station brought challenges with working around other trades and operatives within the Power Station. In addition to those, of course, raised by the high-risk nature of the existing ground conditions, namely due to the known presence of high levels of high-risk asbestos from the existing building, which was demolished and originally left as contaminants on the proposed new site of the power station.

The Solution

Gallaway coordinated with the client ESB energy to a high level of detail to cross-check the existing records of contaminated ground and service records. In addition, geotechnical and asbestos sampling took place to ensure the nature of the subsoils before the commencement of the works. Precontract and Construction Phase Health and Safety Plans were amended, as were the RAMS, to ensure all parties coordinated the works as necessary.

Carrington Power Car Park
Carrington Gas Facility Logo
Image of Carrington Gas Facility.

Carrington Gas Facility

Project Description

Project: Security Enabling Works and External Civil Engineering.
Client: ESB Ireland.
Contract Responsibilities: Principal Contractor.
Contract: Client Bespoke Contract.
Contract Value: £18,000.
Programme: September 2018 for 4 weeks.

The Overview

Gallaway Construction Limited were contracted as Principle Contractor to design, manage and construct enabling works for security provisions and a new pedestrian-accessed car park around an existing high-pressure mains gas facility site. The site is controlled under the remit of National Power. It provides gas supplies to the newly developed Carrington Combined-Cycle Power Plant (CCPP), using natural gas to generate 884MW of electricity.

The CCPP uses gas and a steam turbine together to produce up to 50 per cent more electricity from the same fuel than a traditional simple-cycle plant. The waste heat from the gas turbine is routed to the nearby steam turbine, which generates additional power. Carrington consists of two CCPP KA26-1 units. At operating design conditions, each CCPP unit generates 442.3 MW net output. The station generates enough power to meet the electricity needs of one million homes around the Greater Manchester region.

The Challenge

The site conditions were such that the working areas were sensitive from a security viewpoint. Due to restricted working access, all contractors are vetted, movements monitored, and a high-security presence. In addition, the site consisted of restricted space, particularly around the existing live high-pressure gas pipelines and areas around existing structures.

The Solution

Gallaway coordinated between the client ESB Energy and National Grid to ensure the scope of the works and location of existing services, sensitive elements of the site and the do’s and don’ts were clearly explained before commencements of any paperwork, let alone live works on site. In addition, Gallaway completed both the Pretender and Construction Phase Health and Safety Plans and issued the RAMS to both National Grid and ESB Group for checking and approvals before inducting all operatives onto the proposed site with the provision of permits to works and highly specific toolbox talks.

After carefully considering the existing asset drawings, the site set out after CAT scanning and planning the works. Works were still completed with hand excavations and the removal of spoil from the compound areas by hand. In addition, excavations under fencing for outcoming CCTV and ducting were completed within the day shift to maintain security provisions.

Image of Carrington Gas Facility.
Image of Carrington Gas Facility.
Carrington Gas Facility
Carrington Gas Facility Logo
Featured image of Bolton Skylink.

Bolton Skylink

Project Description

Project: Skylink Bridge at the Transport Interchange, Bolton.
Client: Bolton Council and Transport for Greater Manchester.
Contract Responsibilities: Specialists Ceiling System, Plastering and GRP Systems.

The Overview

Gallaway were initially contracted to complete the specialist supply and installation of the bespoke metal suspended ceiling system on the Skylink bridge, connecting the new Bolton bus interchange with Bolton Railway Station. As the scheme developed, and with completion and a high profile handover rapidly approaching, Gallaway were further contracted to complete the end closure details to the Skylink, with metal studwork, plastering and GRP enclosure works at the interface with the metal ceiling system. Furthermore, Gallaway were then requested to undertake considerable making good of the existing floor tiling and decoration works.

The Challenge

At the time of Gallaways appointment, the design had been partly completed between Baileys and Atkins Global. However it soon became apparent that Gallaway specialist design and site survey expertise was required to iron out a series of design discrepancies and offer design co-ordinations and solutions to overcome differences between the conditions and tolerances inevitably occurring on site and those detailed upon the proposed scheme drawings. The technical difficulties on the metal ceiling system stemmed around the general lack of tolerance afforded by the high quality and high expense proposed metal system.

The Solution

Careful co-ordination was required, with a highly detailed full site survey undertaken, to check the tolerances on the existing steel and cladded frame. The Gallaway design team collaborated with the designers to offer options to overcome the tight tolerances resultant from the proposed product. Interfaces with roller shutter doors, lighting, PA and CCTV systems were required to ensure future maintenance in design was captured for ease of maintenance whilst not compromising the security requirements on this heavily trafficked public walkway.

Project management on site and co-ordination was critical, with collaboration with existing client trades on site but moreover, with the procurement and programming of deliveries for the complex bespoke ceiling system.

Further project management complexities towards the end of the project were encountered with a number of cross subcontract planning and programming challenges to ensure all works were completed by the extremely short handover period.

Image of Bolton Skylink.
2nd image of Bolton Skylink.
3rd image of Bolton Skylink.
1st Image of Bolton Skylink.