Installation of a Marsh Ultra Polylok 110PE Installation
Background
Cory Group commissioned Mantair to assess and replace a failing sewage treatment system at their Riverside Resource Recovery (RRR) Energy from Waste (EfW) Facility in Belvedere, Kent. Following initial site inspections and a trial excavation, it was determined that the structural integrity of the existing system had failed. The structure was severely compromised, with walls caving in, and the system was undersized for the facility’s future plans.
Complicating matters, the existing treatment plant was heavily encased in a dense wet pour reinforced concrete, making removal extremely challenging. Given site restrictions, including the presence of underground services, installing a new system in an alternative location was deemed unfeasible. Consequently, Mantair proposed the installation of a Marsh Ultra Polylok 110PE Sewage Treatment Plant in the same footprint as the existing system.
Comprehensive Project Management Approach
Mantair adopted a comprehensive project management approach to oversee every stage, both pre-installation and throughout the works. This ensured a seamless process, with risks mitigated and all challenges addressed efficiently, often adapting our approach at times.
Project Challenges & Key Considerations:
- Health and Safety: Meeting Cory Group’s exemplary health and safety standards was a key priority, ensuring our work aligned with their rigorous protocols and industry-leading safety practices. Our team underwent Cory’s NCP training programme to meet their rigorous health, safety, and operational standards.
- Site Constraints: Limited working space due to surrounding infrastructure, including an overhead ventilation tunnel.
- Complex Excavation: Unlike standard concrete, the existing system was encased in exceptionally dense wet pour concrete and reinforcement mesh, requiring careful excavation and extended removal time. Our team adapted by using specialist equipment to break down and extract the old structure efficiently.
- Deeper Excavation Needs: A larger-diameter tank was chosen to fit within the available footprint, necessitating a deeper elongated excavation and increased requirements for shoring.
- Bespoke Structural Design: We worked closely with structural engineers to develop a design that prevented any impact on the existing building’s foundations.
- Structural Reinforcement: Due to the site’s operational nature, the installation was upgraded to a vehicle load-bearing standard, incorporating additional reinforcement mesh, concrete seating rings, and heavy-duty ductile iron covers.
- Installation of a Pump Station & Extended Pumping Main: As part of the upgrade, we installed a pump station and extended the pumping main to improve overall system performance and efficiency.
- Uninterrupted Facility Operations: Given the facility’s 24/7 operations, it was essential that our installation allowed for continuous functionality without disruption to prevent any loss of productivity. To ensure this, we meticulously planned our schedule to prevent any impact on operations, enabling the facility to maintain seamless efficiency throughout the project. This included:
- 24/7 Tankering Support: To facilitate the installation, effluent had to be continuously pumped out to keep the site operational.
- Movement of Machinery: With the facility’s heavy goods vehicles continuously delivering waste, we planned our work to ensure safe and uninterrupted movement around our site, making health and safety our top priority.
- 24/7 Availability Throughout the Project: We remained on-call 24/7 during the two-week installation period to swiftly manage any unexpected challenges.
- Critical Sensor Compliance: The facility’s furnace fans operate based on temperature sensors, requiring careful monitoring to ensure compliance with strict tolerance levels. Our installation adhered to these requirements without disruption.
Installation Process
- Decommissioning & Removal:
- The existing system was emptied and decommissioned.
- The heavily encased concrete structure was carefully broken down and removed.
- Excavation & Groundworks:
- The excavation was carefully monitored, ensuring shoring and sheet piling were implemented as required.
- Installation of the Marsh Ultra Polylok 110PE System:
- The new treatment plant was carefully lowered into position.
- A reinforced concrete surround was applied to secure the system.
- The installation was upgraded to vehicle load-bearing standards to accommodate heavy vehicles in the area.
- Pump Station & Extended Pumping Main:
- A new pump station and extended pumping main were installed to enhance wastewater treatment performance.
- 24/7 Tankering Support:
- To ensure uninterrupted facility operations, AA Turners provided round-the-clock tankering services, maintaining continuous waste management during the installation.
- System Connection & Commissioning:
- Effluent connections were established, allowing a seamless transition from the existing system.
- A new kiosk housing the control panel and air compressor was installed.
- The system was tested and commissioned to ensure full compliance with Environment Agency and Building Control regulations.
- Safe Machinery Movement:
- With Cory’s heavy goods vehicle operations ongoing, our scheduling ensured safe and unrestricted site access.
Project Outcome: A Future-Proofed Wastewater Solution
Despite challenges during installation, Mantair successfully completed the project on time and within budget. Mantair successfully delivered a high-performance, compliant, and efficient sewage treatment system without disrupting Cory’s critical waste processing operations. The new installation ensures enhanced wastewater treatment efficiency, full regulatory compliance, and long-term reliability.
As an approved Marsh Industries installer, Mantair provided Cory Group with a comprehensive manufacturer’s warranty and will now be implementing a bespoke maintenance programme to ensure the system continues to operate at optimal efficiency.
A special thank you to Ashley from Marsh for the referral, as well as AA Turners, Sunbelt – Non-Mechanical & Colchester Division, and SRC Concrete for their support in delivering this project.
For more information on our services, contact us: 01255 853890 | enquiries@mantair.com
