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 Whitefield Drive construction project.

Whitfield Drive

Project Description

Project: 12 Whitfield Drive, Milnrow.
Client: O’Connell East Architects.
Contract Responsibilities: Main Contractor.

The Overview

The scheme was to provide an open plan kitchen/living space extension with bi-folding doors and to extend the bedroom above to include a large rear balcony with glass hand railing to the full rear elevation of the property.

The Challenge

The extension and alterations were to improve the property for our client’s young son, who was disabled and needed an open-plan living area. The family remained in occupation of the property during the building works, which added complexity to the building.

The Solution

Close client liaison with the Architects and family was paramount to ensure the works were completed with minimum disruption and daily cleaning of the property. Considered coordination of the works and our ability to change the proposed sequencing to suit our client’s changing requirements resulted in a smooth operation and complete customer satisfaction.

Whitefield Drive residential construction project image 1.

Whitefield Drive residential construction project image 4.

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.

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.

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.

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.

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.

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.