Sludge Packaging Plant (SPP1)
Background
The Sludge Packaging Plant (SPP1) will be responsible for hydraulically receiving legacy sludge from the First Generation Magnox Storage Pond and processing it into a product suitable for long term storage or disposal. It will be made up of two compartments; the buffer storage facility and the process and export plant.
Work commenced on site clearance in November 2005, and involved the demolition and clearance of a number of redundant facilities. Site preparation was completed in September 2007, and following construction of a perimeter the area was moved out of the Separation Area improving accessibility and risk to workers.
Challenges
Restrictions due to the sensitivity of adjacent facilities - which preclude the use of many conventional construction techniques such as tower cranes, telescopic jib cranes and large placement booms for concrete, have provided the biggest challenge to this project so far.
The next two anticipated challenges that are likely to face this project include the delivery and installation of the ECV (Effluent Collection Vessel) and Pipe Bridge which will connect the Magnox Fuel Receipt, Storage and decanning facility with SPP1.
The ECV vessel will be the largest load delivered to SPP1 site. Transportation of the ECV will require alterations to the road signs, barriers with the separation area and will involve the re-routing of emergency escape routes. It will then be transported on a self-propelled modular transporter and then fitted into the ECV cell on a rail transfer system. A large amount of surrounding infrastructure will require civil re-work. In addition, the Separation Area security fence line will have to be further extended and re-categorisation will need to be undertaken.
Due to crane restrictions in the area surrounding the adjacent facility, all options which involve cranes were excluded. Because of this, the team will need to use a falsework superstructure to support the construction of the Pipe Bridge. Again, the logistics associated with transporting the superstructure will also prove challenging given the proximity of the project.
Achievements
The first concrete pour of the new structure took place on Tuesday 6 May 2008. MP for Copeland, Jamie Reed, pressed the button to start the pour, as well as receiving a cheque for £1,000 for charity, the result of excellent performance in the SPP1 safety accumulator scheme.In February 2009, the first concrete pour on the buffer cell was completed marking a halfway stage for the team. The pour took the total volume of concrete poured on the project to 2360 cubic metres, or 400 mixer wagon loads, since May 2008. This takes the project past the 50 per cent mark, in terms of volume of concrete cast.
The project has also fixed 550 tonnes of reinforcing steel, almost all of which has had to be done manually.
Up to date figures of the fixed reinforcement (654 tonnes) and poured concrete (2750 cubic meters) show that even with the severe safety restrictions that the team are bound to, construction of the SPP1 Buffer is progressing forward safely and with quality firmly in mind.
Sludge Packaging Plant
