Past Project

Belvedere

Resource Recovery Facility

0 Project Value

0 Year Programme

0 Peak Workforce

Project Overview

Completion of all FRC works on the Belvedere Energy From Waste.

Works Included, large pile caps, bases, soffits, columns, walls, access ramp/bridge and a 60m x 25m x 27m high slip form to construct the waste bunker.

The scheme was extremely sensitive and each and every milestone was achieved by the collaborative approach used by the entire management team.

Project Details

Client Costian

Principal Contractor Tier 1 Contractor

Project Value £9 Million

Sector Major Infrastructure

Location Belvedere, United Kingdom

Duration 2008 – 2010

£9M Total Project Value

120+ Peak Operatives On Site

24 Month 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

The scope of works involved the completion of all Fibre Reinforced Concrete (FRC) works at the Belvedere Energy from Waste Facility. The project consisted of multiple structural concrete elements including large pile caps, bases, soffits, columns, walls, access ramp and bridge structures, as well as the construction of a large waste bunker using slipform construction techniques. Due to the complexity and programme sensitivity of the scheme, works were delivered through a highly coordinated and collaborative management approach to ensure all key project milestones were successfully achieved.

Foundations and Structural Concrete Works

The works included the installation and completion of major reinforced concrete structural elements forming the base and main framework of the facility. Key activities included: Construction of large reinforced concrete pile caps Installation of structural bases and foundation elements Construction of reinforced concrete columns Installation of reinforced structural walls Construction of structural soffits All works were completed using Fibre Reinforced Concrete (FRC) to meet design specifications and structural load requirements. Reinforcement installation, formwork erection, concrete placement and finishing were carried out in accordance with engineering drawings and quality standards.

Slipform Waste Bunker Construction

A key element of the project involved the construction of the waste bunker structure using a continuous slipform construction method. Structure dimensions: Length: 60 metres Width: 25 metres Height: 27 metres The slipform operation required continuous monitoring of alignment, reinforcement installation, and concrete placement to maintain structural integrity throughout the process. The method allowed for efficient construction while maintaining strict quality and engineering tolerances.

Access Structures and Infrastructure

The works also included the construction of several reinforced concrete access structures required for operational functionality within the facility. These works included: Construction of a reinforced concrete access ramp Installation of a structural access bridge Reinforcement fixing and formwork installation Concrete pouring, finishing and curing Integration with surrounding plant structures These elements ensured safe and efficient access for plant operations and maintenance activities.

Health and Safety Management

Due to the scale and complexity of the works, health and safety management was a key priority throughout the project. Safety measures implemented included: Comprehensive site-specific risk assessments and method statements (RAMS) Daily site safety briefings and toolbox talks Continuous monitoring of working at height operations, particularly during slipform construction Strict adherence to PPE requirements and site safety regulations Regular safety inspections and audits by site management The proactive safety culture on site ensured that works were carried out efficiently while maintaining a strong focus on workforce safety and risk prevention.

Labour Resource Management and Delivery

The successful delivery of the works relied on the effective mobilisation and management of a skilled labour workforce. Key responsibilities included: Provision of experienced concrete operatives, steel fixers, formwork carpenters, and supervisors Coordination of labour resources to meet key programme milestones Flexible labour allocation to support critical construction phases such as slipform operations Close collaboration between site management, subcontractors, and labour teams Maintaining productivity levels while ensuring safety and quality standards were met The structured labour delivery strategy ensured that sufficient skilled personnel were available at all stages of the project, allowing the programme to progress efficiently and meet all required deadlines.

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.

Programme Sensitivity and Tight Milestones

Challenge: The project was extremely programme-sensitive, with multiple structural elements required to be completed within strict milestone deadlines to allow follow-on trades and plant installation to proceed without delay. Solution: A collaborative planning approach was implemented between the management team, engineers, and subcontractors. Labour resources were carefully scheduled and adjusted to meet key construction phases, particularly during major concrete pours and slipform operations. Regular progress meetings and programme reviews ensured that potential delays were identified early and mitigated, enabling all major milestones to be achieved on time.

Complex Slipform Construction for Waste Bunker

Challenge: The construction of the 60m × 25m × 27m waste bunker using slipform techniques presented significant engineering and operational challenges. Continuous concrete pouring and reinforcement installation required precise coordination and monitoring to maintain alignment, structural integrity, and quality. Solution: A dedicated management and engineering team was assigned to oversee the slipform operation. Continuous monitoring of vertical alignment, reinforcement installation, and concrete quality was maintained throughout the process. Labour teams worked in coordinated shifts to maintain uninterrupted construction, ensuring the structure was completed safely and within specification.

Maintaining High Safety Standards on a Complex Construction Site

Challenge: The scale of the structural works, combined with activities such as working at height, heavy lifting, and continuous concrete operations, created significant safety risks that required strict control. Solution: A strong safety management system was implemented across the site. This included detailed Risk Assessments and Method Statements (RAMS), daily toolbox talks, and continuous supervision by site management. Safety audits and inspections were carried out regularly to ensure compliance with site regulations. This proactive approach helped maintain a safe working environment while allowing the project to progress efficiently.

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