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South Hook

LNG Tanks

0 Project Value
0 Year Programme
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Project Overview

BCL completed the contract to build five pre-stressed concrete containment tanks for liquefied natural gas (LNG) at the new South Hook LNG Terminal near Milford Haven in Pembrokeshire, Wales. The tanks are a massive 94 metres in circumference and 31metres high, with a domed concrete roof slab rising a further 12metres. The project took two years to complete with up to 600 operatives on site at any one time. The new South Hook terminal, costing a total $1 billion, will store LNG from a new plant being built in the State of Qatar, close to Saudi Arabia, and is sourced from the country’s North Fields. One of the world’s largest construction projects, which is due to supply 20% of the UK’s natural gas needs by 2008. Natural gas is liquified and reduced in volume by colling to -160 degrees centigrade. This enables it to be economically shipped to the UK, where it is offloaded, stored in tanks, then re-gassified and fed into the gas network. Not only technically challenging, the project offered logistical challenges to the team, due to both the remote location but also the need for constant slip forming whilst building the tanks.

Project Details

Client Taylor Woodrow
Principal Contractor Tier 1 Contractor
Project Value £175 Million
Sector Major Infrastructure
Location Milford Haven, United Kingdom
Duration 2006 – 2008
£
£175M Total Project Value
#
600+ Peak Operatives On Site
M
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

BCL was contracted to construct five pre-stressed concrete LNG containment tanks at the South Hook LNG Terminal. Each tank measures 94 metres in circumference, 31 metres high, with a 12-metre domed roof. The project involved complex slipform operations and large-scale logistics over a two-year period, with up to 600 operatives on site at peak, delivering a technically and logistically challenging scope of works.

Foundations and Substructure

The substructure works provided the essential base for the tanks, including: Excavation and preparation of tank foundations Installation of reinforced and pre-stressed concrete base slabs Placement of embedded components for tank walls and roof integration Quality control of concrete and reinforcement to meet design specifications These works ensured a structurally robust foundation for the large LNG tanks.

Tank Wall and Dome Construction

The main structural works involved the continuous slipform construction of the cylindrical walls and domed roof: Installation of pre-stressing tendons and reinforcement cages Continuous concrete placement using slipform techniques Monitoring of verticality, alignment, and formwork integrity Construction of domed roof slabs with post-tensioning to meet engineering requirements This method allowed for efficient, high-quality construction of all five tanks.

Access, Platforms, and Temporary Works

Supporting the main works, access and temporary structures were provided to ensure safe and continuous operations: Erection of scaffolding, working platforms, and temporary ramps Installation of temporary supports for slipform equipment Safe material delivery and equipment access to tank perimeter Coordination of temporary works with the ongoing slipform operations These provisions ensured efficiency and uninterrupted workflow throughout construction.

Health and Safety Management

Given the scale, height, and continuous operations, safety was a top priority: Implementation of site-specific Risk Assessments and Method Statements (RAMS) Daily toolbox talks, safety briefings, and PPE enforcement Fall protection systems for working at height and safe lifting procedures Continuous monitoring by supervisors and regular safety audits This proactive safety management ensured zero major incidents and compliance with UK construction regulations.

Labour Supply and Resource Management

The project’s success relied on effective labour mobilisation and management: Deployment of skilled operatives, pre-stress technicians, concrete finishers, and supervisors Flexible labour allocation to support continuous slipform operations Coordination of multiple shifts to maintain productivity Close collaboration between subcontractors, management, and on-site teams This structured approach enabled the timely and efficient delivery of all five LNG tanks.

Project Gallery

Key stages and completed elements of this major infrastructure programme.

Key Challenges & Solutions

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

Continuous Slipform Operations at Scale

Challenge: Constructing five large LNG tanks with a circumference of 94 m and heights up to 31 m plus 12 m domed roofs required continuous slipform operations. Any interruption could compromise alignment, quality, and programme delivery. Solution: Dedicated slipform management teams monitored verticality, reinforcement placement, and concrete quality in real time. Continuous concrete pours were carefully scheduled, with phased reinforcement installation and formwork adjustments, ensuring consistent progress while maintaining high structural standards.

Logistical Challenges of Remote Site Operations

Challenge: The South Hook site’s remote location created logistical challenges in delivering materials, equipment, and plant, particularly during peak construction with up to 600 operatives on site. Solution: A structured materials and resource management plan was implemented, coordinating deliveries, storage, and on-site movement. Temporary access routes, platforms, and ramps were installed to ensure uninterrupted construction, supporting safe and efficient operations for all trades.

Maintaining Safety During High-Risk, Large-Scale Works

Challenge: The scale of the tanks, combined with working at height and heavy lifting during continuous slipform pours, posed significant safety risks. Solution: A proactive safety culture was enforced through site-specific RAMS, daily toolbox talks, fall protection systems, and constant supervision. Regular audits and monitoring ensured compliance with UK safety regulations, allowing works to progress efficiently without major incidents.

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