Callow Stourport

Upgrades to a bulk fuel storage and distribution facility within the flood plane of the River Severn, to ensure reduced risk of spills from the bunded tank structure and also penetration into the bunded area by flood water from the nearby river. Works consisted of the removal of concrete slabs to allow redundant bulk oil storage tank demolition, infill of voids from the tank removal, new concrete slabs, provision of new RC bund wall, access ramp and Armco barriers to newly repurposed bund area. Renewal of all floor joints. All completed whilst the facility remained live and incorporated the client’s operational and emergency procedures, as well as limiting impact on neighbouring businesses.

£ 0 k
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Integrated Delivery Team

Montel worked with both the design team and specialist bund sealant supplier to overcome difficulties provided by the removal of elements of the old structure and sealing of new against old. Standard details and special fabrications combined to ensure 100% installation of a stainless steel waterbar at all junctions of old structure against new and all penetrations through the new bund wall. All waterbar elements and reinforced concrete slabs delivered by the skilled in-house team, with the sealant supplier having an overview on the quality of the installation of their products.

Montel worked with the client’s specialist M&E contractors to enable removal or adaption of controls and circuits, either made redundant or planned to be re-routed to suit the structural upgrades.

Specialist demolition/drilling equipment and operatives were employed to cut or break out existing features as well as drill the 3000+ dowel and starter bar holes needed.

Specialist joint sealant partners were employed to renew the bunded area floor joints.


Adopting a Collaborative Strategy

Every aspect of the project had to consider the nature of the facility – a fully functional fuel storage and distribution depot – with it’s limitations and need for RA’s and permit systems to limit risks.

The works were planned to limit impact on the operational aspect of the fuel depot by keeping as much of Montel’s welfare, access and storage as possible to a rear section of the yard, usually used to park a fleet of tankers. By using strategic concrete pour sequencing and up to 62m long reach concrete pumps, Montel were able to minimise the number of pours whilst optimising efficiency of the concrete pumps and shuttering system.

Neighbours were consulted about the works to enable pours and pump positions to be arranged to suit all parties. Signs and posters were displayed in advance to notify all affected parties.

Works were planned to avoid the client’s busiest times and advance preparations discussed and agreed for a pump to access the operational fuel loading gallery area for one short period of time. The only incursion into the operational area.

The sequencing and execution proved so smooth and trouble free that Callow Oils commented on the lack of disruption to their operations – expecting far more interaction and problems!

The shuttering system was planned and organised in advance of the works starting with consultation and recommendation from our FRC partner on the best type and supplier. Due to the limited access for lifting appliances, a relatively lightweight and easily erected/dismantled system was chosen. The pour sequence was designed to limit the number of pours and distance shutters had to be moved for each section of wall pour.


Encouraging Innovation and Learning

Montel’s in house skilled team were introduced to the specialist stainless steel waterbar system and under close scrutiny and QA of the supplier, installed every aspect of the seal to the bottom of the new wall, every vertical joint and every special fabrication to overcome obstacles and features. Every aspect was photographed and documented prior to pouring. This allowed the FRC partner to solely concentrate on reinforcement and shuttering to maximise efficiency.

Using the technical input from material suppliers and contractors, Montel were able to value engineer items like the resealing of the floor joints. Using a partner very experienced in sealing airfield and MOD refuelling facilities gave both a financial and program advantage that we were able to pass to the client at tender stage.