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Isle of Grain

LNG Tank 5

0 Project Value

0 Year Programme

0 Peak Workforce

Project Overview

The construction of the new LNG storage tank at Isle of Grain LNG Terminal forms part of the Capacity 25 (CAP25) expansion project, designed to increase the terminal’s storage capacity and strengthen the UK’s energy infrastructure. The project includes the development of a 190,000 m³ full-containment LNG tank, incorporating a 9% nickel steel inner tank and a pre-stressed concrete outer shell constructed using slipform techniques. Once complete, the expansion will enable the terminal to supply up to 33% of the UK’s gas demand, further enhancing national energy security.

Bowercross Construction Labour (BCL) supplied the skilled workforce required for the slipform construction of the outer concrete tank structure, supporting the main contractor team delivering the project. The slipform operation was carried out on a continuous 24-hour basis, with the BCL workforce completing the structure in just 21 days of uninterrupted construction. The works formed a critical phase of the project, requiring careful coordination, precision concrete placement, and highly skilled labour to maintain structural accuracy throughout the continuous slipforming process.

Project Details

Client National Grid

Principal Contractor Taylor Woodrow

Project Value £175 Million

Sector Energy

Location Isle of Grain, United Kingdom

Duration 2021 – 2026

£

£175M Total Project Value

#

500+ Peak Operatives On Site

M

5 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

Bowercross Construction Labour (BCL) supplied skilled labour and supervision for the construction of the new LNG storage tank at the Isle of Grain LNG Terminal, as part of the Capacity 25 (CAP25) Project. The project involved the construction of a 190,000 m³ full-containment LNG tank, incorporating a 9% nickel steel inner tank and a pre-stressed concrete outer shell. The tank forms part of the expansion of the UK’s largest LNG import facility and will help increase terminal capacity to support up to 33% of the UK’s gas demand. BCL’s workforce played a key role in the slipform construction of the outer concrete structure, completing the slipform operation in 21 days through continuous 24-hour working.

Slipform Concrete Tank Construction

A key element of the works was the continuous slipform construction of the pre-stressed concrete outer tank wall. Scope included: Assembly and commissioning of slipform systems Installation of reinforcement cages and embedded components Continuous concrete placement and finishing operations Monitoring of vertical alignment, wall thickness, and structural tolerances Coordination with engineering teams to maintain quality standards The slipform operation was conducted continuously over 21 days, ensuring structural integrity and programme efficiency.

Structural Interface and Tank Integration

BCL supported structural activities associated with the integration of the tank components. Key activities included: Reinforcement installation for the outer concrete shell Coordination with teams installing the 9% nickel steel inner containment tank Structural preparation for post-tensioning and pre-stressing systems Quality inspections and compliance with engineering specifications These works ensured the successful integration of the outer concrete structure with the inner LNG containment system.

Temporary Works and Construction Logistics

Due to the scale and height of the structure, extensive temporary works and logistical planning were required. Scope included: Installation of temporary working platforms and access systems Coordination of concrete delivery for continuous slipform operations Crane lifting operations for reinforcement and equipment Material handling and storage within the constrained site environment These temporary works enabled safe and efficient construction during the continuous slipform phase.

Health and Safety Management

Safety was a critical priority due to the height of the structure, continuous operations, and heavy construction activities. Safety measures included: Implementation of site-specific Risk Assessments and Method Statements (RAMS) Continuous supervision of working at height and lifting operations Daily toolbox talks and safety briefings for all operatives Monitoring of fatigue management during 24-hour shift rotations Strict adherence to PPE and site safety regulations These procedures ensured the slipform works were completed safely throughout the continuous construction programme.

Labour Supply and Workforce Management

BCL provided a skilled and flexible workforce to support the delivery of the slipform construction. Responsibilities included: Supply of experienced slipform operatives, steel fixers, concrete operatives, and supervisors Workforce planning to support continuous 24-hour operations Coordination of shift patterns to maintain productivity and safety Close collaboration with the principal contractor and engineering teams Through structured labour management, BCL enabled the successful completion of the slipform structure in 21 days of uninterrupted construction, supporting the timely delivery of this major energy infrastructure project.

Project Gallery

Key stages and completed elements of this major infrastructure programme.

Foundation works in progress

Key Challenges & Solutions

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

Working Within a Live LNG Terminal

Challenge: Construction took place inside the Grain LNG Terminal, which is an active gas import facility. This meant strict safety controls, limited access routes, and coordination with ongoing terminal operations to avoid disrupting LNG processing and shipping activities. Solution: Detailed planning and permit-to-work systems were implemented to ensure construction activities were carefully coordinated with terminal operations. Work zones were clearly defined, and regular safety briefings and communication between the construction team and terminal operators ensured that all activities were carried out safely and without interfering with the facility’s operations.

Complex Structural and Engineering Requirements

Challenge: An LNG storage tank is a highly specialised structure designed to store liquefied natural gas at extremely low temperatures (around -162°C). Tank 5 required precise construction of multiple layers, including the reinforced concrete outer tank, insulation systems, and the inner cryogenic steel tank. Solution: Specialist contractors and engineers were involved throughout the project to ensure that materials, welding procedures, and insulation systems met strict LNG industry standards. Quality control inspections and testing were carried out at every stage to ensure the tank could safely withstand cryogenic temperatures and operational stresses.

Mobilising a Large Labour Force

hallenge: The construction of LNG Tank 5 at the Grain LNG Terminal on the Isle of Grain required a significant workforce at peak periods, with over 500 operatives working on the project across multiple disciplines including civil works, steel fixing, mechanical installation, welding, and specialist LNG tank construction. Managing such a large workforce presented challenges in terms of site access, inductions, safety compliance, coordination between trades, and maintaining productivity across different phases of the build. Solution: To manage this effectively, a structured labour mobilisation plan was implemented. This included phased recruitment of skilled operatives, comprehensive site inductions, and strict health and safety procedures to ensure all workers were compliant with site regulations. Work was organised into coordinated teams with clear supervision and shift structures, allowing different trades to operate efficiently without conflict. Regular planning meetings and communication between contractors ensured labour resources were deployed where needed, helping maintain productivity while safely managing a workforce of over 500 personnel on site.

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