Derby Energy from Waste Facility

Project Description

Hambleton Steel were given instruction by Interserve as part as major developments for Sinfin Derby, a planned £145m Energy from Waste (EfW) plant. Instruction included structural steelwork development for the Turbine Hall, FGT Hall, Ash Bunker and MBT Hall. Our work was also inclusive of fabrication and build of the trusses, metal decking, open grid flooring, Intumescent paint, cladding.

Challenges l Solutions

As well as ensuring the different intumescent paint specifications, meeting requirements for each member, depending on the area they are situated, we were also faced with major variations along the way.

Requirements for the structure included various SCI (steel-concrete interfaces) which presented our design team and on-site team with challenges. There were various interfaces on concrete/steel to be considered at the stage of design and when being installed on-site. To ensure stress mitigation, extensive coordination from design to site was required.

Our team erected roof trusses in part of the FGT (Flue Gas Treatment) Hall, over pre-installed equipment. Due to their size, the trusses had to go to site piece small and be assembled on site using Tension Controlled Bolts adjacent to the erection front so they could be lifting straight into position. Similarly, steelwork was erected around the pre-installed Turbine.

Part of the MBT Hall included a pc plank floor which meant cranes could not stand within the footprint. The MEWPs were stood inside, for access, and we worked together with the clients to find a loading solution. The MEWPs would only operate down an agreed safe area running along the building. Timber sleepers which were laid on top of the PC slabs, allowing for the MEWP point loads to be reduced and distributed therefore not damaging the pc floor planks. When near completion, the client came back to us with changes to meet their own amendments to their equipment and operations including various over-head cranes.

Supporting the client, Hambleton Steel went back to completed areas, reviewing each area and providing retrofit solutions for the fatigue, ensuring support for each different overhead traveling crane. This meant working with the client to understand the different weight and size of cranes and eliminating fatigue as well as working around the client’s equipment which had now been installed and in place.

This project required fully galvanised solutions throughout as well as various truss solutions. The truss requirements were considerable, with the client’s varied operations, and this meant fabrication was extensive. Not only in production but also ensuring the sequences were ready to go to site as per programme.