industrial construction and fabric maintenance services

contents
Industrial services introduction Health and safety commitment sector experience Food processing industry Offshore industry Petrochemicals industry Pharmaceutical industry Power industry Shipyards and offshore yards Steel industry 1 2 4 5 6 7 8 9 10 service solutions Total access Blasting, painting and coating Acoustic insulation Thermal insulation and tracing Encapsulation and shelters Fireproofing and fire prevention New build and temporary works 12 13 14 15 16 17 18 case studies Centrica Energy Corus Steel Works The Forth Rail Bridge Langage Energy Centre Lignite Power Plant Lindsay Oil Refinery Port Arthur Refinery SABIC South Hook LNG Terminal 20 21 22 23 24 25 26 27 28

Operating in 39 countries, Harsco Infrastructure specialises in two core market sectors: providing construction services and industrial maintenance services. Within the construction sector we offer an innovative and engineered range of scaffolding, access, powered access, formwork, shoring and site safety services. Available for contracting, rental or sale, these services are ideally suited to large non-residential and infrastructure projects where close coordination with major contractors and specialist sub-contractors is critical. For the industrial maintenance market we work with major facilities operators and contractors to supply multi-disciplined services on plant shutdowns, upgrades and maintenance projects. Products and services include the provision of total access solutions, insulation, painting, blasting, encapsulation and cleaning.

application solutions Clients come to us for our proven expertise and worldwide capabilities in:
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Global experience Harsco Infrastructure is the combination of three long-established Harsco companies: SGB and Hnnebeck in Europe, the Middle and Far East, and Patent in the Americas. Together we offer almost 300 years of combined specialist experience in our fields. We have gained vast reservoirs of expertise on construction sites and industrial facilities around the world, allowing us to develop a range of services tailored to the requirements of todays international construction and industrial clients.

Safe solutions for construction and maintenance High productivity, cost-effective solutions Engineering and applications knowledge

With over 6,500 employees worldwide, our knowledge, insight and experience are at the heart of our customer service. This is backed up by an industryleading range of products, and the resources to ensure that even the most complex project requirements are sourced and delivered on time.

industrial services introduction

Harsco Infrastructures extensive, international experience in the petrochemical, energy and manufacturing sectors has enabled us to develop a range of specialist services to meet the individual requirements and minimise maintenance and new build costs of each plant and facility.
shutdowns During a shutdown, it is vital that many different actions are carried out before production can be started. In a mandatory or necessary shutdown, we have a clear coordination point where we organise and manage all activities, internally and externally, to ensure that the various phases are carefully matched as downtime can be expensive. We work with a long-established maintenance team of experienced employees and through our structured and well-disciplined approach, we can guarantee that a task never takes longer than strictly necessary. Planning based maintenance Maintenance and fault isolation is essential for preventing damage. Together with the client, we develop detailed long-term maintenance plans to engineer the right solution. The planned maintenance approach avoids ad hoc solutions, resulting in manageable maintenance costs. Our on time reporting capabilities highlight the savings in energy consumption costs and reduced risk Corrosion Under Insulation (CUI). new build construction The construction of power stations, processing plants and refining facilities often creates some of the most complex building challenges in the world. Working around live equipment and constructing unusually high, heavy or deep concrete structures emphasises the importance of working with a trusted supplier of formwork, shoring and access equipment. Backed by our engineering expertise and global experience of working on projects where these situations are common, we can help you build and also maintain your industrial project all from one trusted supplier.

Health and safety commitment

Throughout Harsco Infrastructure the safety of our staff, our customers and the public is our highest priority. It takes precedence over all other aspects of our business.
In health and safety, our record (AFR) currently sets a standard for the industry. This requires constant effort in all aspects of risk management, process control, training and communication. Our responsibility is to exercise safety leadership and maintain a safety conscious working environment at every level of our operation. We are dedicated to making this attitude part of our culture and everyday activities.

Working in partnership with you We work closely with our customers to ensure that clear standards of safety competence, cooperation and communication are strictly observed throughout a project. We conduct regular safety reviews, checks and inspections and work proactively with customers and other contractors to ensure we create a safe working environment for everyone working on or around our equipment. Working safely is the best way of keeping to budgets and deadlines.

the industrys most comprehensive safety programme Harsco runs the access industrys most comprehensive programme of safety training. It is ongoing at all levels from site toolbox talks and safety workshops to advanced safety management and leadership courses.

Our safety communication plans include a comprehensive safety manual for managers and supervisors backed up with product user guides and safety notes, technical data sheets, a regular in-house safety magazine and webbased safety updates. Our range of award winning films including The cost of accidents and In the real world have also been widely used throughout the construction industry. Our core health and safety principles:
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Safety is a line management responsibility Working safely is an essential element of employee performance Line management has a responsibility to train all employees to work safely Safety adds value to Harsco customers, stockholders and employees

All injuries and occupational illnesses are preventable All construction and operating exposures can be reasonably safeguarded

Help us help you If you would like help with any aspect of safety management on your site, or you would like further safety information about any of our products, please contact us on 0844 335 8860 or visit www.harsco-i.co.uk

sector experience

Sector experience food processing industry

In terms of plant, machinery and technology, the food processing industry is becoming more sophisticated every day. Standards of safety and hygiene are following suit. This is why Harsco Infrastructures first meeting with the customer is so important in getting a detailed picture of the company, what it produces, and what the site specific requirements are for safe and hygienic plant installation, maintenance, review or repair. Our industry knowledge and experience help establish the compliance parameters that will govern our procedures, and choice of materials and tools.

Before maintenance projects can start, precautions have to be taken machines and production lines must be physically shielded to prevent contamination or parts and materials getting into the production process. All our materials and equipment, including scaffolds, are specially cleaned before delivery and installation, and all our technicians wear protective clothing while on site, such as dust-free overalls, masks and overshoes.

Air-flows, work-flows and wasteflows are also considered in an effort to reduce the impact on the working environment. One of the food-industrys key requirements is that dust formation must be prevented during insulation work. To comply with this, all our insulation and cladding is as far as possible pre-fabricated, and only non dust-forming materials are specified.

Sector experience offshore industry

Offshore oil and gas production is an ongoing operation, 24 hours a day, 7 days a week, in some of the worlds most hostile environments. Hundreds of specially trained Harsco Infrastructure operatives support some of the worlds most renowned companies in this field, ensuring that your operations continue safely, smoothly and with minimum costly downtime.

Our Preventive Maintenance Programme (PMP) solutions are based on a multidisciplinary approach to maintenance for wellhead, compression, production and satellite platforms. We pre-fabricate insulation materials and supply site-specific scaffolding systems based on minimal components for ease of erection. To optimise labour costs on offshore platforms, our operatives are multifunctional - besides their expertise in scaffolding and insulating, they are qualified professionals in painting, welding, tracing and rope access.

In offshore emergencies, it is vital that staff are appropriately trained to take immediate action to ensure the security of all crews as well as the plant. All our operatives are therefore required to complete specific offshore training programmes, including courses in first aid and firefighting. Logistical planning is equally crucial to cost-effective work on offshore platforms. We bring considerable experience in devising expert, sitespecific logistics, including scheduling of flights to platforms, to ensure the smooth implementation of solutions that are thoroughly safe and make a positive impact on lead time.

Sector experience Petrochemicals industry

Harsco Infrastructure has proven experience in new construction, maintenance and turnarounds in the petrochemical industry. Our multidisciplinary approach enables us to marshal and coordinate a whole spectrum of skills, expertise and operatives, and to guarantee the timely implementation of scheduled maintenance programmes. We always work in close partnership with operating management to provide world-leading standards of safety.

At the start of each project, we work on identifying customer specifications and carry out a risk-assessment, taking into account the nature of the product being generated at the site. Our extensive experience with volatile substances and working in hazardous environments makes us a partner of choice for many of the worlds biggest petrochemical companies. Scaffolding erection, cladding, insulation installation or removal, heat exchanger cleaning and repairs are all aspects of our work at petrochemical plants. In addition to this we can also inspect equipment, measure wall thicknesses and undertake valve expansion.

In a single production shutdown, any combination of these may have to be carried out before production can be restarted. Because downtime is expensive, we take a tight and welldisciplined approach, to guarantee that no production stop ever takes longer than strictly necessary. Working together with our customers, we develop long-term maintenance schedules indicating priorities and deadlines for months and years ahead. The planning-based maintenance approach prevents disruption and expensive ad hoc solutions, resulting in more controllable maintenance costs. It also means reduced energy consumption, while the pre-emptive inspections for Corrosion Under Insulation (CUI) reduce costs further.

Sector experience Pharmaceutical industry

In the pharmaceutical, chemical and biotechnology industries, the implications of contamination mean that hygiene standards are even stricter than in the food industry. Operatives, materials and tools must all meet cleanroom conditions. Harsco Infrastructure has developed particular expertise and experience in this field, and our teams are specifically trained and practiced in working in pharmaceutical environments.

Before any project starts, our experienced team will take additional precautions ensuring we fully understand and appreciate all of the site dangers and risks. The maintenance site location is isolated using a special sealing unit and solution and kept under constant pressure. This prevents dust and minimises the risk of contamination to the production process. All our technicians wear hygienic, dustfree, protective clothing. We use only

fibre-free and dust-proof insulation materials, which are prefabricated off-site wherever possible. Air-flows, work-flows and waste-flows are all considered in an effort to reduce the impact on the working environment. We will work closely with you to ensure that you continue to meet Good Manufacturing Practices (GMP) and that any production shutdowns or outages can be resolved as quickly as possible with our support.

Sector experience Power industry

Despite increasingly stringent environmental regulations and public awareness, the worlds consumption of energy is still rising. New power plants are being developed and the capacity of existing infrastructure is being upgraded. Harsco Infrastructure has comprehensive, international experience and expertise in the construction and maintenance of major energy facilities. From low-rise gasfired power plants and waste-to-energy (WTE) incineration plants, to high-rise nuclear, coal-fired and biomass plants, we have the experience required throughout the energy market.

Power plant sites impose particular demands for vigilance regarding safety. Working in the vicinity of highvoltage equipment, working at height, and working in high-temperature environments all require specific training, which has to be continually refreshed. All our operatives attend sector-specific training programmes and managers hold regular toolbox talks to ensure the individual security requirements of the customer and the environment are respected and understood. Our highly trained teams use their work at height experience to provide safe scaffolding and access solutions on some of the worlds tallest stacks and boilers as part of their daily routine. We

also pre-assemble and deliver a range of high-quality insulating materials designed to cope with extreme temperatures. Downtime for the power industry is expensive, even when planned. Outages are also detrimental as they impact instantly on the public. Our global network of stock and service centres of excellence enable us to provide rapid responses for both emergency shutdowns and the scheduled turnarounds that help prevent them. We are trained in and committed to supporting the plant through every phase of its life-cycle from commissioning to decommissioning and the life of the plant in between.

Sector experience shipyards and offshore yards

Harsco Infrastructure is a recognised partner in many large naval and commercial shipyards, dockyards and platform maintenance docks and we understand that our maritime customers have unique requirements. From specifying details such as seawater resistant insulation and cladding materials, to designing the most cost-effective strategies for getting back in the water, we have the ingenuity and the resources to handle it.

Naval construction projects, whether for governments, companies or individuals, impose very particular demands. We work with special shipbuilding scaffolding systems that enable the contours of a vessel to be perfectly tracked. The system can also be constructed as freestanding to comply, for example, with the requirement for a race standard paint finish in yachts. For specialist finishing work we provide sealing solutions to create dust free working environments. Floating offshore units brought in to dry docks for repair, maintenance or modification require particular expertise in making workplaces accessible. Our track record in this field includes the provision and installation of

specially-designed scaffolding throughout the unit, including the deck and internal floating elements, to facilitate replacement of equipment, piping, cable tray systems and ventilation ducts. Offshore platform design and the spaces operatives sometimes have to work in are getting more complicated and compact. The pressure this creates is further complicated by the variety of disciplines and trades all working simultaneously during the construction or maintenance project, not to mention the strict schedule. Through years of experience, we are well-attuned to these scenarios and have a wealth of advice to offer in minimising inefficiencies and risks.

Sector experience steel industry

Harsco Infrastructure is a major supplier to the worlds steel industry. We specialise in industrial insulation, scaffolding, tracing, fireproofing, painting and blasting on raw material processing facilities. 160 production sites in over 30 countries employ Harsco Metals, our sister company, for their expertise in on site logistics for raw materials, semi-finished and finished products.

Our teams are well aware of the logistical challenges on any production site and bring exceptional experience in providing effective service. In large industrial areas, there may be considerable distances to cover between the various plant sites, including coke ovens, pellet and sinter plants, blast furnaces, steel plants, hot and cold strip mills and gas holders. Our expertise in logistical planning ensures the most effective and timely delivery of materials and deployment of operatives to different factories. Working on steel production sites also means that employees must be fully aware of the operating requirements of each plant. Our operatives are

trained to work safely in dusty or dirty environments and in environments with extreme temperatures. Our teams are also well-versed in the risks of on site logistics, such as trains or conveyors. The experience we have of designing and delivering solutions for hightemperature environments impacts our choice of materials. We only supply and fit high quality insulation capable of withstanding temperatures up to 1000C. Our global network of stock and service centres of excellence, and our highly trained, expert teams, enable us to provide rapid responses for both scheduled turnarounds and emergency shutdowns.

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service solutions

Service solutions total access

Harsco Infrastructure has developed a unique multi-product approach to the provision of access on each project, giving our customers an optimised solution. We have one of the most extensive ranges of product options and solutions in the industry, from traditional or systemised scaffolding to mechanical access.
Our project management teams will work with you to develop a comprehensive access plan for your industrial new build, shut down or maintenance programme. Selecting the optimum combination of products to provide an access solution which ensures maximum on site productivity without compromise to safety. standard and customised solutions The flexibility of our product range increases our versatility, and we are adept at finding intelligent solutions for the most complex projects, whether working on the construction of a new installation or a routine facilities maintenance programme. We are one of the worlds few fully integrated suppliers with the capability to offer a total access solution. Based on your project requirements, rather than our catalogue, we develop a bespoke access plan based on the most appropriate access solution for each elevation. Whilst considering the sensitive, high risk environments you work in, our solutions can be based on any combination of access and labour, from MASTCLIMBERS or MEWPs, to scaffolding, aluminium or GRP access towers - all from one supplier. engineering capability Our in-house engineers and designers have in-depth knowledge of the specific regulations, requirements, codes and qualifications required. In addition, they have years of experience of working on some of the worlds largest and most complex projects, live environments and multiphased projects, where the design of low-impact solutions are critical to success. Our engineers apply their ingenuity and specialist expertise, along with the latest software technologies to design solutions that both solve/preempt problems and save money for you. Innovations can be new ways of using old methods, new applications for existing products, or something completely radical. Critical to our success are our dedicated research and developments teams, which are constantly striving to develop more innovative and efficient solutions to every day problems found by our customers.

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Service solutions blasting, painting and coating

Harsco Infrastructures specialist surface preparation and protective coatings teams work to extremely exacting standards, using the latest technology to deliver advanced solutions to our customers.
surface preparation We offer a range of surface preparation solutions with varying work method approaches according to the specialities on site. This ranges from fine blast material such as glass bead for the removal of residues from highly sensitive equipment, to chilled iron and steel shot used mainly in areas where reclamation and re-use can take place. Hydro blasting/uHP jetting Before applying protective coatings, standard high pressure water jetting is an excellent solution for the removal of contaminants from almost every industrial surface. Ultra High Pressure (UHP) jetting is an ideal surface preparation method for the removal of substances such as old coatings containing lead. Our operatives are trained to the highest standards through the recognised governing body The Water Jetting Association (WJA). As with all work undertaken in this environmentally sensitive area, we ensure full compliance with the Control of Lead at Work Regulations. specialist coatings We are able to offer high quality solutions producing the ultimate standards of protection for todays corrosion requirements. An extensive range of anti-corrosive resistant primers, build up coats and finishes, polyurethane and epoxy resins are available to produce excellent standards of protection for steel and most metal surfaces.

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Service solutions acoustic insulation

The prevention of noise through acoustic insulation across a wide range of applications is an important specialist area of Harsco Infrastructure. Our acoustic insulation assists in creating a comfortable working environment around machines, construction operations, music and equipment, along with meeting the strict health, safety and environmental regulations placed on limiting noise production.
standard and customised solutions We have various options to create a relatively quiet working environment, including the use of screens, dampers and barriers. Which precise measures are necessary to neutralise the source of the noise is dependant on the situation. The specialist expertise and training of our employees helps us to provide you with the right solution. By combining various measures, we are able to solve almost every acoustic problem, even in special circumstances.

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Service solutions thermal insulation and tracing

Thermal insulation of industrial installations is one of the core activities of Harsco Infrastructure. In many production processes it is essential to closely monitor the temperature. For example, enabling people to work in the close vicinity of heat sources, maintaining the temperature of piping in a critical production process or complying with specific legal requirements.
Our specialist insulation teams have years of experience fabricating and installing protective thermal insulation and cladding, including temperatures up to 1000c, Corrosion Under Insulation (CUI) and cryogenic applications. Our products have been tested in the harshest of conditions and have always met the performance life and safety criteria of the facilities we are servicing. multi-disciplined approach Harsco Infrastructure annually supplies hundreds of kilometres of heat control tracing (electric or steam) to all industrial sectors, from the food to petrochemical industries. This means that we have a great deal of experience in formulating and implementing ready made solutions. We finely tune insulation and tracing to each other, so that optimal temperature management is guaranteed. In addition, we ensure that every installation complies with the relevant environmental, quality and safety requirements. the right solution We work with a range of thermal insulation materials, from mineral wool to acrylic nitrile rubber, in combination with aluminium, stainless and galvanised steel claddings. We are able to fabricate for all types of equipment, including vessels, pipe work, inline fittings, columns and tanks working in a variety of metals to suit the application.

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Service solutions encapsulation and shelters

Harsco Infrastructure offers a wide range of options for the encapsulation of your structure. Whether you need weather protection for personnel or sensitive structures, or to protect the environment from noise, light, dust, fumes, or contamination and containment, we will have a suitable solution for your project.
By cladding the entire structure, you can eliminate the unwanted effects of changes in pressure and wind suction that are typical for traditional sheets and netting. This allows work on the project to continue, whereas traditional methods may have delayed the completion. Protection using encapsulation Meeting the latest legislation requirements, and made from an adaptable, fire resistant and waterproof material, encapsulation can be applied to even the most varied faades. Especially useful in situations where work and residue material could damage the environment, cause material damage to property or where adverse weather could delay the project. Encapsulation allows for the whole work area to be completely covered, preventing leakage of undesired material from the work area, whilst protecting both workers and the inner structure. Possible damage to the encapsulation can be easily repaired and it is possible to create sealed holes for run-through structures.

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Service solutions fireproofing and fire prevention

Fire can cross over from transits in cables, tubing and pipes into surrounding spaces. To ensure the fire safety of your staff, premises or project, it is necessary to cover all transits in walls, ceilings and floors with non-flammable materials. Harsco Infrastructures fireproofing installations meet all the legal requirements for fire safety, and our annual inspections offer you piece of mind.
Our fireproofing system has been specially developed to prevent the risk of fire spreading. We map out all transits in a building and ensure the correct level of insulation safety. After this, an annual inspection is carried out. During these checks, existing transits are approved and upgraded where necessary and new transits are secured. We also take care of fireproofing by putting fire resistant mortar on plinths and weight-bearing constructions.

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Service solutions new build and temporary works

access Harsco Infrastructure is one of the few fully integrated suppliers in the world with the capability to offer a total access solution. Our unique system of services complements our innovative range and we are adept at finding intelligent answers to even the most complex projects. We carefully consider the sensitive, high risk or public environments you work in and can provide a complete package including the hire, sale and labour for a whole range of equipment including MASTCLIMBERS, suspended cradles, MEWPs, scaffolding and aluminium or GRP access towers.

formwork When you are on complex nuclear, power, or process plant projects you need confidence in the people you are working with. By partnering with us you can expect unrivalled engineering expertise and application knowledge. Our solutions can be based on any combination of formwork and shoring, from walls, slabs to climbing and edge protection - all from one supplier. Based on your specific project requirements, rather than our catalogue, we develop a bespoke temporary works plan based on the most appropriate formwork and falsework solution for each and every concrete pour.

site safety We provide help, advice, products and solutions to help you work safely. Our all-inclusive packages from a single source include leading edge, fall protection, fall prevention, acoustic noise protection screens, barriers and worker protection systems. temporary accommodation We offer portable accommodation that is secure, practical and durable, whilst providing a pleasant and efficient environment for your team. Our flexibility means that you can utilise even the most awkward space. We also provide a range of environmentally sustainable units that incorporate self-sustaining features and comply with the latest regulations. Working closely with you to assess your needs, we can deliver the right building for you with the minimum of disruption to your operation.

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case studies

Case study centrica energy, Peterborough Power station, uK

Project challenges
Opened in 1993, Peterborough Power Station owned by Centrica Energy, is a medium sized, gas-fired plant with an output of approximately 360MW. Like most modern power stations, Peterborough has an air-cooled condenser grid which avoids the need for clean water from the local supply and reduces the use of chemicals in protecting the boilers and steam turbine. We were approached to devise an access solution for painting the main supply pipes to the cooling grid. Access from below is made difficult by the fragile condenser panels which extend out at an angle below the pipes. Heavy scaffolding was also impractical due to the lightweight structure of the cooling grid which cannot support heavy loads. Our solution was a pair of specially-designed mobile steel gantries supporting conventional powered cradles. The cradles move both vertically and horizontally along the gantry, while the gantries can be winched along the pipes on guide wires. The gantries are mounted on two sets of off-set, jack-up wheels which allow them to ride over the pipe ribs. The cradles can be lowered to the walkway at the base of the condenser panels for easy access. Once work on each pair of pipes is complete the entire gantry/cradle assembly is craned to the next row. The entire assembly, painting and re-positioning operation is designed to be carried out without affecting the normal operation of the power station.

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Case study corus steel Works, redcar, uK

Project challenges
Steel giant Corus produced 3.5 million tonnes of steel at its 3,000 acre Redcar site every year and in the process consumed high quantities of gas to fuel its furnaces. A crucial link in the production cycle,the gas holder needed to be periodically refurbished. We were asked to devise an access solution to allow grit blasting, panel replacement and re-painting of the steel clad structure. Working with specialist fabricator SBV Fabrications, we installed 11 MASTCLIMBERS. To access the 22 flat faces of the gas holder, we erected single-masted platforms against each alternate face and then re-erected them on the remaining faces to complete the refurbishment. Installation of the platforms was complicated by the presence of a large amount of pipework, tanks and other obstacles at the base of the gas holder. To overcome this, a 7m steel bridging structure was designed to transfer the weight of the masts to the ground. We also designed a special H-bracket to tie the MASTCLIMBERS onto the gas holder without damaging the structure. This is one of a number of term maintenance contracts which involves call outs and shut downs either planned or emergency.

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Case study the forth rail bridge, scotland, uK

Project challenges
On 21st January 1890, two trains first crossed the Forth Rail Bridge, travelling across two and a half thousand metres of track suspended nearly 50 metres above the Firth of Forth. This feat of engineering remains an iconic structure and today requires equal feats of ingenuity to maintain. The exposed location, the extraordinary structure, 190 train movements per day and the busy shipping lane below, make this famous bridge one of the ultimate access challenges. Scaffolding the bridge starts by reversing the conventional ground-up approach. The evident complexity of the bridge, built with more curves than angles, means that every scaffolding member has to be individually designed, fabricated and suspended in position high above the Forth. Access platforms then have to be encapsulated in plastic sheeting, to prevent old lead paint being shot-blasted into the environment and to protect the new, glass flake epoxy paint from the weather while it dries. The bridge is well over a 100 years old, but it takes 21st century technology and expertise to keep it in safe use, making our experience on live industrial maintenance invaluable. We have already supplied two and a half thousand tonnes of bespoke steel scaffolding and at least another one thousand are anticipated before the project is complete.

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Case study langage energy centre, Plymouth, uK

Project challenges
The 847 Megawatt Langage Energy Centre near Plymouth is the first gas fired power station to be constructed in the South East of England for several years. The 400 million combined-cycle power plant is being built by main contractor Alstom Power on behalf of Centrica Energy. We were asked to supply a comprehensive portfolio of access equipment, based on our record of delivering safe and effective solutions that meet programme deadlines. We have provided a total of 200 tonnes of CUPLOK system scaffold, two MASTCLIMBERS and two 27m high mobile elevating work platforms (MEWPs). The equipment was used to provide access for exterior cladding as well as for plant installation and fitting out of the main Turbine Hall and Heat Recovery Steam Generator Building. Several large birdcage scaffolds were created using CUPLOK system scaffolding to provide access to the underside of the distinctive curved, roof overhang.

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Case study lignite Power Plant, boxberg, Germany

Project challenges
General contractor Strabag AG approached us to develop an efficient formwork and scaffolding solution with prompt delivery of materials, including various special formwork solutions, for this new power plant block. The construction of the new Lignite Power Plant in Boxberg, is one of the most challenging projects we have undertaken in recent years, both in terms of formwork and scaffolding. Sophisticated load bearing structures created from our modular scaffolding system provided significant savings in time and cost in the construction of the main beams. Instead of bracing the building completely using frame scaffold supports at every level, forces were transferred using modular scaffold towers arranged at selected points. In this way it was possible to start other work on the lower levels before the final storey was completed. Even where the production of the main beams demanded a working platform outside the building, this could be achieved without difficulty using system components.

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Case study lindsey oil refinery, immingham, uK

Project challenges
Totals Lindsey Oil Refinery at Immingham is the UKs third-largest refinery, processing 200,000 barrels of crude oil per day. For the construction of their new Hydro Desulphurisation plant, contractor Jacobs needed multi-purpose access for all trades involved in this complex project the largest of its type currently under construction in the UK. The project has involved the construction of approximately 10,000 scaffold structures utilising over 3,300 tonnes of scaffolding equipment and up to 180 operatives. Key products employed were CUPLOK system scaffolding, conventional tube and fittings and a range of beams for larger spans. Providing safe access for all trades, as well as the logistics of managing the supply and welfare of a large workforce in a relatively remote location, required careful planning and constant liaison with all the project teams. Our solution included the provision of a skilled, specialist management team based at our on-site compound incorporating supervisors, administration, safety and logistics personnel. Harsco Infrastructure now provides an access and insulation support service which includes planned and unplanned outages.

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Case study Port arthur refinery, texas, usa

Project challenges
A joint venture between Shell and Saudi Aramco, the Motiva Enterprises Refinery in Port Arthur, Texas, expanded to become the largest in America and one of the top ten in the world. As part of this project, approximately 53 new refinery modules were assembled at Cianbros Modular Manufacturing Facility in Brewer, Maine, each requiring a vast amount of scaffolding to set all the various pipes and structural beams in place. With very little continuity in design, as each module differs from the next, there is only one-eighth of an inch margin for error, as all structural, piping and functional elements have to fit precisely. The harsh winters in Maine add to the challenges of working outside at this scale. Harsco Infrastructures scaffold system was chosen for its high levels of adaptability, which means different lengths and heights can be accommodated without interruption, and projected levels of productivity can be maintained. Scaffolding specifications for this vast and complex project have, to date, drawn on 90% of the component range. During winter assembly, some modules were wrapped in more scaffolding and plastic sheeting to provide shelter from the weather. Finally, after each module was completed, they travelled by barge from Maine, around the Florida coast and then west to Texas. Once in Port Arthur, the modules were assembled together to form the refinery. This mega-project will increase the refinerys current capacity of 275,000 barrels per day to more than 600,000 barrels per day.

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Case study sabic, Wilton, uK

Project challenges
SABIC, (Saudi Arabia Basic Industries Corporation), is one of the worlds leading manufacturers of chemicals, fertilizers, plastics and metals. In Europe they are a major producer of polymers, chemicals and innovative plastics. Their Wilton and North Tees chemical complex in Teesside is one of the UKs largest chemical plants, producing ethylene, propylene and butadiene as well as housing a major logistical facility incorporating large scale storage capacity, a cross-country pipelines network and distribution and shipping services. To accommodate the maintenance and upgrading of the plants Butadiene Columns, SABIC required a 64m high weatherproof access structure which could accommodate the stripping, cladding, painting and re-cladding of these complex vessels whilst the towers remained operational.
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Working around live plant places heavy responsibility on designers, managers and erectors and highlights our traditional strengths of safety, technical innovation and attention to detail. To deliver the painting and insulation requirements rather than opting for conventional tube and fittings scaffold, we devised a solution using CUPLOK system scaffolding. Not only was this able to accommodate the many pipe-runs connecting into the tower, it provided clear working platforms, free from diagonal braces. It was also substantially quicker to erect the CUPLOK system, saving the client time and money. The scaffold structure was clad using the latest breathable sheeting to allow for any plant leakage without compromising blasting and painting operations, and topped with a ventilated roof structure spanning across the towers.

Case study south Hook, lnG terminal, Wales, uK

Project challenges
To create weatherproof access solutions in a exposed coastal environment for the new build of a regasification plant for customer Taylor Woodrow. For the construction of this major new regasification plant in West Wales, we developed and erected a series of weatherproof access solutions for the installation of insulation for the tanks and pipelines. The insulation work had to be carried out under protected and dry conditions a particular challenge in view of the exposed coastal position of the plant. Our solution was developed using a modular aluminium roofing system. Despite its light weight, it was able to span large widths. The structure was covered with a translucent covering, allowing all work to be carried out in daylight with full protection against the weather.

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All information in this brochure is correct at the time of going to press. Harsco Infrastructure reserves the right to change products details or withdraw products at any time. Harsco Corporation Trademarks Companies within the Harsco Group are the proprietors of, amongst others, the following trading names and trade marks: Harsco, Harsco Infrastructure, SGB, Huennebeck and Patent.

 2011 Harsco Infrastructure Services Ltd, Harsco House, Regent Park, 299 Kingston Road, Leatherhead, Surrey, KT22 7SG, UK. 0211/BCR/3k/H316

Or visit us at: www.harsco-i.co.uk

For further information on Harsco Infrastructure, please contact: info_infrastructure@harsco.com