Project Overview
Hayward Utility Services was appointed to deliver the civil engineering works for the repowering of an existing FlexGen (STOR) facility, replacing 26 x 500kW diesel generators with 14 x 1MW gas-powered generators.
Our scope included the demolition of the existing reinforced concrete foundations, ground reprofiling and the design and construction of new reinforced concrete plinths to support the upgraded generating equipment. The project formed part of a wider investment to increase generating capacity while modernising the site’s infrastructure.
The Challenge
Unlike a new-build development, this project was delivered within a live operational generation facility where space was limited and existing infrastructure had to remain protected throughout the works.
The demolition of 26 reinforced concrete plinths, combined with restricted access and ongoing site operations, required careful planning, innovative construction methods and close coordination with the wider project team to maintain safety and programme.
Our Solution
To safely undertake the demolition works within the confined site, Hayward adopted robotic demolition equipment, reducing manual intervention while improving safety, precision and efficiency.
Material arising from the demolition was removed using a conveyor belt extraction system, allowing waste to be transported safely from restricted working areas while minimising plant movements and reducing disruption across the site.
Following demolition, our team completed the ground reprofiling works before constructing the new reinforced concrete foundations designed to support the upgraded 1MW gas generators.
Our scope included:
- Demolition of 26 reinforced concrete foundations
- Ground reprofiling and site preparation
- Civil and structural design of replacement foundations
- Construction of reinforced concrete plinths
- Sustainable management and recycling of demolition materials
Sustainability
Sustainability formed an important part of the delivery strategy.
All demolition materials generated during the project were processed locally, with 100% diverted from landfill.
Concrete was crushed and recycled for reuse, steel reinforcement was recovered for recycling, and local processing significantly reduced transportation distances and associated carbon emissions.
The Outcome
The civil engineering works were successfully completed, enabling the repowering of the existing FlexGen facility with higher-capacity gas-powered generation.
By combining innovative demolition techniques, careful planning and sustainable construction practices, Hayward delivered the project safely while minimising disruption to the operational site and achieving 100% recycling of demolition waste.
Project Highlights
- Repowering of an operational FlexGen (STOR) facility
- Replacement of 26 diesel generators with 14 x 1MW gas generators
- Robotic demolition in a live operational environment
- Conveyor extraction system for confined working areas
- 100% of demolition waste recycled
- Zero reportable incidents
- Delivered safely with minimal operational disruption
