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