Nuclear Past Project

Sellafield

Evap D Project

0 Project Value

0 Year Programme

0 Peak Workforce

Project Overview

BCL provided supervision and all construction trades on the Evap D Project from 2009 until completion in 2018.

This project is the largest nuclear decommissioning project in the UK. We were able to directly employ all our workforce with over 90% recruitment from the west Cumbria area.

Key challenges on this project included, a congested site, a very complex design all based on a very tight footprint.

The project also achieved one million man hours on site without a lost time incident.

Project Details

Client Costain

Principal Contractor Tier 1 Contractor

Project Value £297 Million

Sector Nuclear

Location Sellafield, United Kingdom

Duration 2009 – 2017

£297M Total Project Value

150+ Peak Operatives On Site

8 Year Programme Duration

Our

Scope of Works

BCL delivered a comprehensive package of labour and supervision services across all major construction phases of the project.

Project Overview

BCL provided full supervision and construction trades for the Evap D Project from 2009 until completion in 2018. As the largest nuclear decommissioning project in the UK, the works were complex and executed within a constrained site footprint. The project demanded high levels of coordination to manage intricate designs, limited access, and sensitive nuclear safety requirements.

Civil and Structural Works

Key civil and structural activities included: Excavation, foundation works, and structural support installations Construction of reinforced concrete and steel frameworks for plant decommissioning Installation of containment structures and shielding for nuclear materials Coordination with nuclear engineering standards and QA procedures These works ensured the structural integrity and safe operation of decommissioning activities.

Mechanical, Electrical, and Specialist Trades

CL provided all specialist trades across the project: Mechanical installation, piping, and plant support structures Electrical works, including power distribution and temporary services Installation of nuclear handling systems and containment equipment Integration of multiple trades within a congested and complex site layout The seamless delivery of multi-disciplinary trades enabled efficient progression within tight site constraints

Site Access, Logistics, and Temporary Works

Due to the congested site and tight footprint, extensive planning was required for access and logistics: Installation of temporary roads, platforms, and lifting points Material storage and movement planning to avoid interference with ongoing works Sequencing of deliveries and on-site operations to maintain programme efficiency Provision of temporary services, scaffolding, and hoisting arrangements This careful logistical management supported safe and uninterrupted construction.

Health and Safety Management

Safety was paramount on this nuclear decommissioning project, reflected in achieving one million man-hours without a lost time incident: Implementation of site-specific RAMS and nuclear safety protocols Daily safety briefings, toolbox talks, and monitoring of high-risk operations Continuous supervision for working at height, lifting operations, and restricted areas Strict adherence to PPE, radiation protection, and emergency response procedures A robust safety culture ensured both personnel and environmental protection throughout the project.

Labour Supply and Workforce Management

The success of the Evap D Project relied on a locally sourced, skilled workforce: Direct employment of all trades with over 90% recruitment from West Cumbria Labour planning to match project milestones and high-risk activities Coordination of multi-trade teams to operate efficiently in a congested site Continuous training, supervision, and quality assurance of workforce This approach ensured productivity, high-quality delivery, and local employment benefits.

Project Gallery

Key stages and completed elements of this major infrastructure programme.

Foundation works in progress

Structural frame installation

Reinforced concrete pour

Key Challenges & Solutions

Delivering major works within a complex infrastructure environment presented significant engineering and logistical challenges requiring innovative solutions from our teams.

Congested and Restricted Site

Challenge: The Evap D Project was carried out on a very tight footprint, making material storage, equipment access, and multi-trade operations challenging without interfering with ongoing works. Solution: A detailed site logistics and sequencing plan was implemented, including temporary roads, platforms, and hoisting arrangements. Careful scheduling of deliveries and work sequences ensured that all trades could operate efficiently without causing delays or compromising safety.

Complex Design and Multi-Discipline Coordination

Challenge: The project involved a highly complex nuclear decommissioning design, requiring precise coordination between civil, structural, mechanical, and electrical trades. Solution: BCL provided integrated supervision and multi-trade management, holding regular coordination meetings and using detailed method statements to ensure all elements were installed correctly. Close collaboration between teams minimized clashes and maintained quality throughout the project.

Maintaining Safety in a Nuclear Environment

Challenge: Working within a nuclear decommissioning site presented significant safety risks, including radiation exposure, lifting operations, and confined space hazards. Solution: A robust safety management system was enforced, including site-specific RAMS, daily toolbox talks, PPE compliance, and constant supervision. This proactive approach contributed to one million man-hours on site without a lost time incident, demonstrating a strong safety culture.

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