KGXX Expansion Project
Civil Works Alliance Partner
Selected as the preferred Civil Contractor to join THE ALLIANCE PROJECT, Luddon took on over £9m worth of work which was completed on time and within budget while raising the standard for Civil Contractors.
Computer generated image of the new plant
Safety:
New attitudes to safety have been generated through this project. By the introduction of listening meetings, small rewards for good ideas and continual motivation, our workforce has been encouraged to take ownership of safety rather than have safety as something which is “thrust down their throats”. Safety does continue to be something that requires to be managed but this is made much more achievable when the workforce understands and accepts their role in the safety of themselves and others.Weather:
The winter of 1998/99, when most of the deep excavations were being carried out was to be the wettest for many years. This created conditions that required great determination and stamina from both management and workforce to continually achieve the progress required by the programme.Ground Conditions:
Typical Grangemouth ground conditions with a water table at 1.2m below grade. This means that all excavations must be maintained using pumps to de-water.
Piles at T1006 Foundation
Sewer Diversion:
The diversion of a 630mm diameter HPPE sewer. A distance of 1200m completed in eight weeks with the tie-ins to the existing high-pressure live sewer. The tie-ins carried out during a 6 hour shutdown co-ordinated with the local water authority and completed during the small hours of a cold and wet November night.Piling:
A total of 2050 No. reinforced concrete piles driven to an average depth of 20m. This work completed using 4 piling rigs, to a programme, in a relaxed 5 months period.Deep Excavations:
The construction of an insitu concrete sump required a large cofferdam excavation well below ground water and tidal conditions. This required the constant use of wellpoint dewatering.Deep Drainage:
2400m of concrete lined ductile iron pipe from 900mm to 100mm diameter. Concrete manholes where through innovation it was decided, to great success, that the base and kickers should be precast including all waterbar. Thus avoiding the worst of poor ground conditions.
Furnace & Stripper Bases
Structural Concrete
10,000 m3 of concrete placed in foundations of all descriptions.These varied in size from furnace bases at 390m3 per base to smaller more standard 4-5-6m3 pile caps.
Firemain:
600m of 400mm diameter HPPE pipe have laid jointed tested and connected to the existing live firemain at three separate locations. The main includes the installation of 14No. hydrants and 6No. valves. This work carried out by our own workforce who are trained in the preparation and jointing of this type of pipe.Paving Concrete
12200m2 of Concrete paving 250mm thick was placed in a progressive manor across the project to a sequenced and demandingly tight programme. The aim being to achieve a solid clean working platform for follow on mechanical trades.
Cooling Tower Flume & Pond Base
Holding Down Bolts:
Almost 2000 bolts of all sizes were incorporated in the construction of the main foundations some individual bolts weighing as much as 0.25 tonne each. A further 4000 bolts (approx.) bolts were then cast into random pipe supports and plinths.Table top slabs on columns:
Three reinforced concrete structures were required to carry compressor plant. These comprised a slab 1.2m thick elevated at 9m above grade and supported on 20No. 900mm square concrete columns.Cooling Tower Pond:
The base and retaining pond for 5 timber cooling towers. The base (62m x 22m) was cast in four pours totalling over 1500m3. The perimeter and flumes were then constructed with walls in various heights from 3-5m high including the casting insitu of several large diameter pipes.
Concrete Paving Progresses
Completion:
At substantial completion of the works described here Luddon dropped into attendance mode, working as service provider for our alliance colleagues.The provision of yard supports and minor sundry foundations as the project progressed through the mechanical, electrical and commissioning phases.
Finally the completion of all road surfacing and dressing out of gravel chipped areas prior to handover to the operators of the new working plant.
