Careys Civil Engineering was contracted in 2016 to deliver basement and superstructures on a new Energy from Waste (EfW) plant in Ferrybridge, Yorkshire. The 83-week contract was awarded by principal contractor, HZI on behalf of SSE. Ferrybridge Multifuel Energy already operates an EfW facility on-site, with this second facility being constructed to boost energy generating capacity in the North of England and process approximately 570,000 tonnes of waste a year.

Adding to our portfolio of energy-related construction projects across the UK and Ireland, we are constructing the sub & superstructure along with associated drainage, service installation and hard landscaping works at the site.

During pre-construction planning, our team made numerous trips to meet the client and principal contractor based in Zurich, producing a fully resourced programme and 3D phasing sketches of our methodology. During this period, HZI specified numerous alterations to the original design, requiring our team to make alterations to our intended approach, including changes to the site logistics plan, location of tower cranes and alterations to site phasing, drainage and landscaping.

Unusually for the project, the client also specified weekly progress reports as opposed to monthly, requiring our teams to produce an incredibly detailed programme of activity and bespoke KPIs to present to the client. 

As a result of our work before the project began, our team identified a six-week time saving in the programme during the water testing of the bunker, presenting a value engineering option to incorporate a tunnel around the perimeter of the bunker. This provided access for inspections, removing this element of works from the critical path and enabling follow-on trades to commence on site early.

Our team also made extensive use of 3D and 4D modelling, creating a virtual model of the slipform rig to test and demonstrate the safety and effectiveness of logistics, access and storage to both HZI and SSE. 

The project represents the largest slipform project ever delivered by Careys, with the rig being designed to negate the use of access ladders and provide exceptional safety when working at height. Our team have implemented night works to keep construction of the waste bunker on schedule, after which the tipping hall and concrete works are to be completed.

Health and Safety performance on the project has been exemplary, with our team receiving a commendation from the client on the performance of the team. Key to this success has been the implementation of the Carey Way and SHED programmes, designed to reinforce best practice in achieving quality and safety across all projects in the Carey Group.

Principal Contractor
Hitachi Zosen Inova
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