Five Fords WwTW

Project Description

Project: New Build & Refurbishment
Client: JN Bentley and Welsh Water
Contract Responsibilities: Main Contractor
Contract: Bespoke form of contract
Project Value: £320,000
Programme: June 2018 to August 2019

The Overview

Five Fords WwTW is a sewage works just outside Wrexham in North East Wales, blending passive and activated sludge treatment.

The total population served by the works in the Wrexham area is around 100,000, and seven tankers per day bring in sludge and domestic sewage from elsewhere in the North East Wales and Chester area.
The MMB and Welsh Water Capital Delivery Alliance set out to deliver the second phase of the Sludge Strategy Aim, the £56.2m North Wales Sludge Strategy (NWSS).

At its heart, the NWSS is a waste management strategy which aims to deliver Opex savings and enable the business to meet the Biosolids Assurance Standards from June 2018.

The other principle drivers are:

Production of an enhanced standard biosolid
Improve dewaterability of biosolid product reducing transportation
Increase solids destruction increasing gas yield and reducing transportation
Reduced reliance on aging assets for sludge treatment

The original project consisted of the construction of two new buildings, these being the Pre- THP and Post-THP buildings. This quickly developed into the refurbishment of the existing Cake Building initially to three of the elevations, and then extending to the full building, including the removal and installation of a new flat roofing system. In addition, Gallaway was also asked to complete the cladding and door installation on two belt reception units.

The Challenge

The install phase of the project was fast-tracked to deliver the Pre and Post THP buildings in time for the already ordered conveyors. Procurement lead design solutions were adapted to ensure steelwork design and lead-in durations were shortened to accommodate programme, and programme resequencing was adopted to allow the installation of the specialist plant and equipment into the building, and to then allow the building to be formed around its contents.

Refurbishment of the existing buildings was a challenge, with the contents of the building requiring cleaning prior to Gallaway
commencement, and the structural steelwork then being surveyed by Gallaway with a full defects report prior to treatment and remedial works.

The latter incorporated new steelwork member strengthening and blast cleaning, and redecoration with a suitable finish for the new proposed building usage.

The Solution

Having delivered several sludge treatment facilities across the sector previously, Gallaway were able to ensure mitigation was put into place to avoid previously encountered issues.

Lessons learnt workshops were held between Gallaway and the clients to capture pertinent points, and closely working with MMB assisted both parties through the process to deliver a high-quality product to the client.

Gallaway embraced technology within the design and procurement phases which MMB and Welsh Water were able to utilise to provide improved direct outcomes, both in terms of plant and equipment selection.

Gallaway were able to design the building around the requirements of this new plant. As part of the delivery team we strived to embrace the latest advances in technology and capturing digital design processes in order to expediate the build programme.

Anchorsholme Park

Project Description

Project: Anchorsholme
Client: C2V+ and United Utilities.
Contract Responsibilities: Main contractor.
Contract: NEC3.
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 £80 million redevelopment of Anchorsholme Park, Fylde Coast,
In this project, Lancashire 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 were constructed for the residents to enjoy, along with sports pitches, facilities, and an outside adventure playground.

The final parts of the development consisted of 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. Therefore Anchorsholme Park was developed to include a new detention tank and outfall under the proposed new seawall and promenade for stormwater disbursal.

The Challenge

Several key stakeholders were 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 groundworks 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 site’s coastal location 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 project. In addition, materials challenges and the selection of client-proposed materials added challenges to the build process to ensure the scheme became workable.

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

The Solution

Gallaway has been involved at all design stages and builds a programme to coordinate 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 direct specialist trades were coordinated from a Health and Safety viewpoint. Whilst ensuring environmental and quality compliances were maintained at the highest levels and ensuring programme delivery on this marquis project.

New Build Fire Stations

Project Description

Client: Balfour Beatty; Fire and Rescue (NW) Limited.
Location: Belle Vale, Burnley, Chorley & Fleetwood.
Contract Responsibilities: Structural, First and Second Fix Joinery and Carpentry Works.

The Overview

Client: Balfour Beatty; Fire and Rescue (NW) Limited.
Location: Belle Vale, Burnley, Chorley & Fleetwood
Contract Responsibilities: Structural, First and Second Fix Joinery and Carpentry Works

The specification for the new fire stations, was drawn up to enhance operational efficiency and also to acknowledge the fire prevention role that is such a crucial part of today’s Fire and Rescue Service. The modern design and functionality of the fire stations had to incorporate a variety of facilities including welfare, meeting and lecture rooms, offices, communal areas and the new in-house smoke house for improved training.

The Challenge

Gallaway’s specific involvement in the construction of the projects was to carry out all works associated with the structural, first, second fix, joinery works inclusive of full fixtures, fittings, equipment and kitchens. Special consideration had to be given to the sites and their physical conditions, materials and types of equipment and the facilities needed. It was necessary for Gallaway to familiarise ourselves with any statutory or imposed restrictions that may have an effect on the execution or completion of the works.

The Solution

The Gallaway principle of constant communication with all teams onsite was fundamental to the success of this project.
Excellence in team selection, forward planning and a well executed site management programme all contributed to the successful delivery of this scheme.

Gallaway is pleased to announce all four schemes were handed over to the client to a high standard of quality, on time and on budget. All four stations are now operational and actively serving their communities.

Image of Burnley Community Fire Station.

Donna Nook Coastal Defence Project

Project Description

Client: Birse Civils.
Location: Humber Estuary, Lincolnshire.
Size: 2,600m flood defence embankment.
Responsibilities: Flood defence structures, New Control
Building, Landscaping and Excavation Works.

The Overview

The construction of a new 2,600m long food defence embankment on land around the Humber Estuary, creating an intertidal habitat through the managed re-alignment and improvement of the existing coastal defences.

Gallaway’s role was to construct reinforced in-situ concrete retaining and outfall structures, including the construction of a new control building to operate the existing pump house.
Landscaping and mass excavation works with associated interface considerations, were required for the installation of the new ductile iron pipework system diverted from the existing pump building through the new outfall structure.

The Challenge

The site is adjacent to an Environment Agency site of special scientific interest, meaning the team had to work around the restrictions of nesting birds, badgers and local wildlife. The project also had to be programmed around the migration of grey seals. Task specific challenges included working below the water table with the continuous consideration of ground water control and running sand.

The Solution

The works were carried out in a series of bays to minimise disruption and to limit plant movement. The construction of the below ground outfall structures was carried out within piled cofferdams to control water ingress, until such time that the embankment was opened up. Mass excavations and water diversion techniques were utilised to aid the works.

Benefits achieved included improved environmental, social and economic outcomes creating 110ha of new intertidal habitat improving the condition of the nationally important wetlands and contributing to national biodiversity targets. This showcase scheme has facilitated further flood defence schemes elsewhere along the Humber, in line with the flood defence strategy.