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Case study - Shepham Wind Farm

We were contacted By Raymond Brown Construction Ltd early 2016 and asked if we would be interested in pricing a control building to house the electrics for a new wind farm consisting of 3 turbines being built just around the corner from us!!

It seemed an opportunity to good to be true.

Raymond Brown Renewables have built wind farm projects that now contribute towards 5% of the UK’s total onshore wind energy.

We were successful in the tender process and commenced on site in May 2016. We had a very tight time scale and had to hit the ground running.

Due to design issues the project started late but with no change in the end date! As a result of this we worked most Saturdays to ensure the lost time was recovered and the required handover date achieved.

The control building is a single storey building formed on complicated sub-structures.

The sub-structure consisted of a reinforced concrete ground bearing slab, a large amount of complicated blockwork walls consisting of blocks laid flat forming either blast walls or single/double skin blockwork to create service ducts and pits to house the large HV AND LV cables leading from the turbines to the switch gear and metering in the control building.

We had to diamond drill twelve openings in the outer substructure walls allowing for two banks of six 200mm diameter ducts to come through. These openings then had to sealed with a specialist waterproof sealant as they would be underground eventually and the water table was very high in the area.

On top of the sub-structure walls we cast another ground floor slab. From this level, we formed 2 large rooms which would house meters and switch gear and two smaller rooms for metering.

All rooms were finished in painted face blockwork with Glasroc fire boarded ceilings, skimmed and painted.

The concrete ground floor slab was painted with an epoxy floor paint and service ducts closed off with GRP floor covers.

Externally we had to install large steel security doors specifically designed for substations. We were given the sizes, this meant we had to have the structural openings almost millimetre perfect as there was no room for error with the metal doorframes, they had to fit!

The external walls were rendered with a coloured waterproof lightweight render Monocouche and we supplied and fitted Kee Klamp handrails around the perimeter to finish.

The roof was formed with roof trusses overlaid with plywood finished off with an artificial slate covering.

Just as we had finished they formed a new access road so that the cranes and articulated lorries carrying the huge sections of turbine which were transported by boat from Holland to Newhaven, could then drive onto site.

The contract was completed on time and the client was very pleased with our progress.

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