B2 Reinforced Concrete Prop Installation, Sellafield

The brief

With DSD Construction acting as subcontractor to Altrad Babcock, this scheme involved the installation of reinforced concrete props in a nuclear facility to allow installation of a large roller shutter door to facilitate future decommissioning works.

Our scope of work on this scheme included:

• Installation of 2 reinforced concrete props at a height of 7.7m above ground level. 

• Input into temporary works designs.

• Installation of falsework and formwork.

• Installation of dowels and threaded rod connections.

• Installation of reinforcement.

• Casting concrete and stripping formwork and falsework.

• Additional minor civils works including breaking out concrete and installing blockwork.

Site conditions:

• High Security Area
• Radiological Controlled Area
• Building Layout & Space Constraints

Challenges & successes

Concrete was required to be cast at a height of approximately 7.7 metres above ground level within a 70 year old nuclear facility with no direct access, presenting both logistical and safety challenges. These were successfully addressed through the development of a detailed temporary works design, which provided engineered support for the concrete pour while incorporating safe and compliant scaffolding access for operatives.

In response to the building layout and significant space constraints, a carefully planned concrete pumping strategy was implemented, utilising a combination of boom, flat, and vertical pipework to enable accurate discharge into the formwork. This approach allowed the concrete to be placed efficiently and safely despite the restricted environment, ensuring the works were completed to the required standard and without disruption.

Outputs & Benefits

Health & Safety: There were zero reportable incidents, resulting in DSD Construction achieving an ‘excellent’ safety rating.

Client Benefits: The work was complete on programme with no non-conformances or defects.