Since 2013, we’ve been working with EDF as part of the Hinkley Point C project in Somerset to build two nuclear power stations. Due to be completed in 2025, these will be the first new nuclear stations to be built in the UK for over 20 years.

When finished, they will generate enough electricity to power approximately five million homes and are set to provide around 6% of the UK’s electricity – all of which will be low carbon.

Laboratory Work

• All electricity generated will be low carbon, supplying 6% of the UK’s demand.
• From our UKAS accredited project lab, we conduct testing for all construction materials.
• To meet the growing project demands, we’ve upscaled our facility, our system, and our team.
• We’ve accumulated 26,000 earthworks tests so far, working hard to match the project pace.
• We trained seven apprentices to join the team, and have set up our own NVQ centre on site.

Materials testing

We’ve been involved in this project since the initial site material trials in 2013. Working from our UKAS accredited project laboratory, we’ve provided an extensive range of sampling and field testing for all construction materials. These include concrete, spray concrete, earthworks, aggregates and asphalt.

Thanks to our first-class facilities, our technicians were able to meet the growing demand of this project, upscaling our team and accreditation capacity as the works moved forward. To date, we have completed sampling and testing on over 9,500 concrete pours, tested over 56,000 concrete cube specimens, and carried out over 4,000 flexural concrete beam tests .

Managing the demands

Over the course of this project, we’ve moved from a small facility to a 60 cabin, open-plan facility, allowing us to grow with the demands of the largest construction project in Europe. Alongside this, we’ve grown our personnel to 50 trained staff and technicians, including laboratory administration and site labour.

With an evolving management system, we’ve accumulated 26,000 earthworks tests to date, including:

• In-situ compaction testing.
• Laboratory classification testing.
• Chemical testing for soil and water sampling.
• Nuclear density gauge compaction testing.

Training and development

In collaboration with the Kier/BAM JV project delivery team, we recruited seven apprentices to the Hinkley Point team. All seven completed B-Tech qualifications, including NVQ LATA Awards, and went on to work with us on the Hinkley project.

We also set up our own NVQ centre within the laboratory. Consisting of an internal verifier and internal assessors, it allows us to offer NVQs internally, to all our staff. The initiative has allowed many staff members to achieve professional membership within the ICE or IOM³.

Enabling Work

• As part of the Deep Dig works , we managed quality control of the concrete and earthworks.
• We installed 202,000m of soil nails and bolts to support the vertical faces of the deep dig.
• We sprayed 104,000m2 of vertical faces of the deep dig.
• We conducted a full ground investigation for the decoupling wall, reducing risk for the site and the team.
• Engaged in the project since 2013, this is one of the largest ventures our team has taken on.

Decoupling Wall and Dry Dock

We were recruited to conduct a complete ground investigation for the ‘decoupling wall’ – a contiguous piled wall which allowed the deep dig to progress, before the permanent sea wall was finished. It’s important to understand the location’s geology before constructing a wall of this kind, so it helped that we were on site. As we already had a firm grasp of the location, we were able to deliver a ground investigation that supported the delicate geology of where we were based - which greatly reduced the associated risks.

Blue Anchor Formation Improvement Works (BAFI)

One of the new buildings in the power station was designed on highly fractured blue anchor formation rock, which needed a complex grouting scheme to avoid seismic settlement.

As experts in ground investigation, our team was recruited to ascertain the requirements for the grouting scheme, before being validated by the Nuclear Regulator. With accuracy vital, we used a digital modelling system to deliver validation in a clear and precise way – leaving no room for error.