76 Tonne CHP Boiler Installation

Sector

Pharmaceutical

Location

Macclesfield, UK

Services

Temporary Works

Completion

June, 2024

OVERVIEW

The CHP Boiler Replacement project involved the installation of a new 76-tonne boiler within an operational energy centre as part of a wider upgrade to ageing combined heat and power infrastructure.

The works formed part of a major resilience and efficiency improvement programme aimed at supporting the site’s long-term operational and sustainability objectives.

Our involvement included the structural assessment and temporary works design associated with the delivery and installation route for the replacement boiler, ensuring the safe movement of heavy plant across sensitive underground infrastructure.

THE CHALLENGE

The proposed installation route for the new boiler traversed directly over a manhole structure connected to one of the site’s primary surface water drainage culverts.

Due to the significant imposed loads from the 76-tonne boiler and associated lifting operations, there was a substantial risk of overstressing or damaging the buried drainage infrastructure.

OUR SOLUTION

A reinforced concrete piled cantilever slab was designed to provide a robust load transfer platform capable of spanning over the existing manhole and preventing direct loading onto the drainage culvert below.

When site conditions prevented the safe removal and replacement of the manhole cover structure, a rapid temporary works solution was developed to maintain the installation programme. This involved the design and implementation of a temporary load distribution arrangement using WAM mats to safely spread construction and installation loads across the affected area while protecting the underlying drainage infrastructure.

The solution enabled the successful continuation of the boiler installation works while maintaining structural integrity and minimising disruption to the operational facility.