Williamsgate WTW

Project Discription

Project: Williamsgate WTW, Cumbria
Client: Balfour Beatty / MWH JV (Advance)
Contract: NCE 3
Project Value: £2,400,000
Programme: June 2019 to June 2021

The Overview

The project involved designing and constructing new water treatment works near Redmain in the Lake District. The proposal was to transport raw (untreated) water from Thirlmere Reservoir to the new plant for production into a freshwater supply. The site had been designed to merge into the natural contours of the surrounding environment, with considerate colour materials and one building incorporating a green roof to help the site blend into the landscape.

Once completed, the site would be capable of treating 80 million litres of water every day and service the Northwest demand with clean drinking water to strengthen the existing network. The new distribution pipes can take the treated water from the site to our service reservoirs, where it could be stored and ready to supply customers in West Cumbria. The new structures included an underground detention tank, Rapid Gravity Filter Building, Control Building, Workshop, Inlet Building and Sludge Building, including internal modelling, MEICA installations and fit-out.

The Challenge

The project’s budgets were keen; therefore, the proposals needed to be rationalised with the consideration of additional build techniques or specifications. The former of the two was difficult because the works represented merely a building fit-out, and the scope for change in techniques was limited. Specifications and finishes, however, needed to be challenged, and Gallaway was pivotal in doing so. Access and egress to the sites were further limited due to other key trade packages, the timeliness of the Gallaway works and access due to working alongside the newly installed tracks. Just-in-time deliveries needed to be carefully considered and managed. Some materials needed to be delivered and stored well before the works commenced to minimise disruption and enable safe access.

Midway through the construction period came the Covid-19 crisis. Gallaway quickly adapted to the considerable challenges the virus brought, from our team’s delivery of the project to maintaining and growing the supply chain as necessary to continue the works on this key status project. Gallaway amended Risk Assessments and methods of working promptly and maintained site operations to deliver on agreed dates through the crisis period and for the critical MCC units and plant to be installed directly from the manufacturer to the site without any standing periods or storage requirements.

The Solution

Gallaway undertook a rigorous Value Engineering exercise by offering a full design and build package and amendments to specifications but within the confines of the performance specifications. Gallaway further offered external building remodelling to the buildings’ shape and elevations, including materials specification, to offer the best value through equally comparable and approved materials, which offered similar aesthetics and provided cost efficiencies through materials themselves and the simplification of construction. The new proposals sought to amend the existing planning application, to enact the changes and design proposals for exterior materials and samples.

As is often the case, the Gallaway programme considerations were governed by the requirement to maintain our client’s key dates for sectional handovers and, in some instances, the handover of individual rooms. Through collaborative planning sessions, Gallaway amended and adapted the build sequence to suit the client’s important critical dates to hand over areas of our working building to specialist subcontractors. In doing so, Gallaway amended the HSEQ considerations on site for our works and those working around other contractors to ensure the works were completed correctly.

Five fords

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.

Five fords
Five fords waterworks
Five fords water treatment works
Stafford Stores

Stafford MDU Stores

Project Description

Project: Stafford MDU Store
Client: Laing O’Rourke for Network Rail via Staffordshire Alliance
Contract Responsibilities: Construction of New Store, Mess and Office Building.
Contract: NEC3.
Project Value: Circa £290,000
Programme: Contract start date September 2017. Contract duration 16 weeks.

The Overview

This project formed the second part of a previously completed scheme by Gallaway at Stafford MDU. This included decommissioning the previously constructed temporary office and store and the new build store building, incorporating a large store area, office and mess facilities.

The works involved designing, constructing and delivering a new store building for Network Rail at their Maintenance Delivery Unit of Wolverhampton Road in Stafford. It comprised a steel frame building with exterior wall and roof cladding, internal blockwork plastered walls, suspended ceilings, mechanical and electrical installations, floor/wall finishes, fixtures fittings, and equipment.

The Staffordshire Alliance project, a joint venture of Laing O’Rourke, Network Rail, Atkins and VolkerRail, has been named the winner of a Collaborative Working accolade at the 2016 UK Railway Industry awards.

The team recently handed over the £250m upgrade to the West Coast Main Line, including 10 kilometres of a new line, under budget and over a year ahead of schedule.

The Challenge

The works were carried out adjacent to the operational West Coast Main Line, with live overhead cables close to the building.

One major challenge was completing the steelwork erection and installing the external cladding, ensuring safe working practices were adopted within our construction methods and by all team members.

This was further challenged by the proximity of the live West Coast Main Line and working around clients and contractors on this operational site.

The Solution

Gallaway coordinated the crane lift plan to ensure limits were imposed on the lifting height to avoid exceeding the safe working distance from the live cables above.

We also utilised GRP Scaffolding and ensured our standard daily briefings and weekly toolbox talks specifically about the task.

Timber baulks, barriers and hoardings were utilised to segregate working equipment to a prescribed safe working distance from the trackside.

Stafford Stores
Stafford stores

Oswestry Water Treatment Works Lime Building

Project Description

Project: Lime Building
Client: C2V+ and United Utilities
Contract Responsbilities: Design and Build Steel Frame, Cladding, Concrete Security Panels, internal Mezzanine and Finishes and Security Doors and Louvres
Contract Value: £139,000
Programme: 7 weeks

The Overview

The Lime Dosing Building on the Oswestry Water Treatment Works treats raw water from Lake Vyrnwy Reservoir. It provides quality water to a million domestic, commercial and industrial customers in Liverpool and Cheshire.

The new plant design included a new clarification process to improve colour removal from the water, modification to the filtration process, disinfection within a new contact tank using lime water, and a new clearwater tank to provide on-site storage of treated water for use as required.

The Challenge

The largest technical challenge on the building was the requirement to undertake the construction stage of steelwork erection and cladding elements around major excavations and the inclusion of the external tank, all of which were installed before the building commencement. In addition, Gallaway was requested to partially erect the steel frame to enable the client installation of various tanks and equipment into the building through the roof before the Gallaway internal building crane installation.

Gallaway was then required to complete the cladding elements in stages, taking the roof and each elevation as isolated elements to aid the client’s intended M&E programme. Similarly, a series of return and isolated visits were requested for the treatment and closure of penetration enclosures around conveyors and incoming services.

The Solution

The Gallaway programme was largely built around the client programme’s requirements, including their requirements for external works and large underground water storage facilities. Gallaway had to be adaptive to accommodate the changing external conditions while attempting to coordinate with the client regularly to establish their weekly requirements. Bespoke flashing closure details were adopted for the conveyor openings. All of which leads to a complex but good quality end product for our client and United Utilities.

Image of Davyhulme Water Treatment Works

Davyhulme Substation, Manchester

Project Description

Project: Substation Building
Client: Scottish Power
Contract Responsibilities: New build substation construction and internal fit out
Contract: NEC3
Contract Responsibilities: £183,000
Programme: 8 weeks

The Overview

Having previously worked on Davyhulme Waste Water Treatment Works, Gallaway was appointed to construct a masonry substation building for Electricity Northwest. The project formed part of the larger £70million redevelopment of the UK’s largest Waste Water plants. The scope and specifications for the substation consisted of reinforced facing brickwork, reinforced blockwork, wind post and roof steelwork, cut timber roofing with a mixture of membrane and tiled roof finishes, external security doors and louvres, all with internal walls, decoration and plastering.

The Challenge

Gallaway was to work around the existing transformers to build the new substation building for the end user Scottish Power. Working in controlled areas, to tight specifications of high quality and full details, Gallaway had a challenging programme period to construct the building to enable Scottish Power to undertake the electrical installations and commissioning works. Subsequently, the substation provided power requirements to enable the operation of the treatment works and, as such, was firmly on the project’s critical path.

The Solution

Gallaway held regular programme and design team meetings with clients, suppliers and subcontractors to remain on the target programme and accommodate specific key sectional completion dates. As a result, coordinating Gallaway contracted works whilst accommodating access for client-based specialist trades within the live building project was achieved through full collaboration with key stakeholders.

Image of Davyhulme Water Treatment Works
Image of Davyhulme Water Treatment Works
1st image of Water Treatment Works Bickerstaffe.

Southport DMZ

Project Description

Project: Water Treatment Works Bickerstaffe.
Client: KMI and United Utilities.
Contract Responsibilities: Construction, Project Management.

The Overview

The existing service reservoir located at the Bickerstaffe WTW site is the hub that provides water to Southport DMZ and the local areas. The demand for this service reservoir varies from 32 to 59 million litres per day (ml/d) depending on the seasonal impact of tourists visiting Southport and the irrigation requirements of the local market gardening industry.

The Challenge

The amp 5 project consisted of constructing new water treatment works at Royal Oak, located adjacent to the existing Bickerstaffe site, with a treated water output of 13 million litres per day. Simultaneously, four existing boreholes at Melling, which had been out of service for several years, have been refurbished to be brought back into supply. In addition, an existing raw water main previously used to convey Melling water to an industrial user in Skelmersdale has been intercepted and extended to supply the new Royal Oak water treatment works.

The Solution

Gallaway’s involvement in the scheme was for constructing the superstructure and internal fit-out of the treatment and administration buildings. In addition, we constructed the top cladding façade and new roof structure inclusive of all structural steelwork and cladding to the rapid gravity feed building.

Image of Water Treatment Works Bickerstaffe.
Image of Water Treatment Works Bickerstaffe.
Second Image of Manchester Square in Blackpool.

Manchester Square, Blackpool

Project Description

Project: Pumping Station.
Client: KMI and United Utilities.
Contract Responsibilities: Construction, Project Management.

The Overview

The Manchester Square pumping station discharges screened foul and surface water sewage from Blackpool into the Irish Sea during periods of storm surge. The existing facility was handed over to United Utilities from Blackpool Council in 1990 and at this time the pumping station ans associated works were not only in a poor state of repair but also visually unattractive. This became apparent when compared to the recent improvements to the promenade, achieved as part of the renewal of the sea defences.

The Challenge

There was an immediate need to ensure that the pumps providing the storm discharges didn’t result in the pressurised chambers under the promenade failing and then leading to the collapse of the public thoroughfare. Temporary remedial works were undertaken by United Utilities which were approved by the council, however, they have not done anything to enhance the overall appearance of the promenade looking obviously industrial and out of place.

The Solution

Gallaway’s involvement in the scheme was to re-clad the existing pump station main building and to construct a new escape hatch building as well as building a single storey extension to infill a corner of the main building to create a garage area. We went on to erect a single storey extension to the seaward elevation of the main building to house the relocated pressure vessel in order to ventilate the site more  appropriately than at present. The works were designed to reinforce the building to prevent seawater ingress and increase safety of the operation.

Image of Manchester Square, Backpool.
Second image of Manchester Square, Backpool.
First image of Manchester Square Blackpool.
Image of Preston & Wigan Railway station.

Preston & Wigan Railway Station Public Toilet Refurbishment

Project Description

Project: Wigan and Preston Railway Station Public Toilet Refurbishment.
Client: Serco and Virgin Rail.
Contract Responsibilities: The temporary provision of toilet facilities and full refurbishment of the existing toilets including new hand railing, corridor cladding and stair nosing and tread works to major circulation areas.

The Overview

The temporary redirection of the general public to new toilet and wash room facilities during the course of the works and the demolition, structure support, strip out and full refurbishment of the male, female and disabled facilities to two major Northwest Railway Station platform main toilets.

The major circulation public spaces such as corridors, under track walkways and staircases refurbishments including demarcation, new wall and ceiling cladding to divert rainwater from the tracks away from pedestrian areas.

The Challenge

To work in very close proximity to the general public in these bustling railway stations to tight deadlines to ensure the seamless change over from the existing facilities to new temporary washrooms to enable the works to take place.

Taking into account sequencing and Health, safety and environmental separation of the potentially intrusive building works from members of the general public and staff was paramount.

The Solution

Careful planning, co-ordination signage and pedestrianisation of certain areas in addition to excellent public relations from all members of the Gallaway build team ensured a smooth transition during the course of the works.

The high specification and robust nature of the required works were completed to an excellent final quality and to the agreed extremely tight programme timescales.

Preston & Wigan Railway Station Refurbishment Taps.
Second Image of refurbished toilets at Preston & Wigan railway station.
Image of refurbished toilet at Preston & Wigan Railway Station.
Featured image of Preston Tunnels.

Preston Tunnels

Project Description

Project: Waste Water Treatment Works, Dry Well Building.
Client: KMI and United Utilities.
Contract Responsibilities: Construction, Project Management.

The Overview

Preston waste water treatment works in part of a £250 million pound project to improve the bathing waters in the North West. Storm water will be cleaned at the sewer network, until it is safe to go back into the rivers and sea.

The Challenge

To construct a 3.5km long 2.85m wide tunnel, situated 30m below ground level to the west of Preston and to include eight tunnel shafts. On completion, the tunnels will hold up to 40 million litres of storm water to prevent overflows into the river Ribble.

Our brief included the production of an evidence-built programme from contemporaneous site records, and a review of KMI’s accepted programmes for robustness and suitability for any delay analysis. We were also required to repair the accepted programme in line with the findings in the review above as well as the need to consider any preparation that may be needed from the impact of the resultant delays with the ground collapse at the terminal pumping station shafts. Having gathered and assessed this information we then drew up a report to identify these delays and calculated the extension of time that would be required by KMI in order to progress through the revised works.

The Solution

The joint venture is a consortium between Kier, Murphy and Interverse. The project is still in progress as part of the United Utilities amp 6.

First image of Preston Tunnels.
Second Image of Preston tunnels.
Image of Preston tunnels.
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.