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Shepham Wind Farm – Pevensey

Client: Knights Brown Limited

Scope of project :
Construct a single storey structure with a blast proof basement to house electrical panels and to receive the incoming cables from three wind turbines.

Hawes Building

THE CONTRACT

Over the past decade, Knights Brown Limited has successfully undertaken the development of 150+ wind farm projects right across the UK. Following a competitive tender early in 2016, this industry specialist commissioned Hawes Building Limited to construct a vital component of its latest, three-turbine wind farm project at Shepham: the electrical control building. Time scales were tight as we went on site in May 2016, and they became even tighter following a delay in the design process. Despite this, by committing to a six-day week we achieved the handover date and successfully delivered on our promise of high quality workmanship and keen pricing – which was what had won us the contract with Knights Brown.

“High quality and standard, finished on time and on budget. Very professional.” was the feedback Hawes Building received from the senior quantity surveyor at Knights Brown.

As the stand-alone contractor, we managed all aspects of this project. The plans specified a complex substructure –combining a reinforced concrete, weight bearing slab with a significant number of intricate block work walls – to support the single-storey control building.

To construct the walls, Hawes Building laid blocks flat, to form either blast walls or single/double skin block work. The resulting service ducts and pits housed large HV and LV cables leading from the turbines to the switch gear and metering in the control building.

Twelve openings were diamond drilled in the outer substructure walls, to accommodate two banks of six 200mm diameter ducts. These underground openings were sealed with a specialist waterproof sealant, since the water table in this area is very high.

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OUR DELIVERY

A second concrete slab was cast at ground level, on top of the substructure walls, then coated with an epoxy floor paint. The service ducts were closed off with GRP floor covers. Our team next built two large rooms, to house control panels and switch gear, with two smaller rooms for metering.

These rooms were finished in painted face block work with Glasroc fire boarded ceilings, then skimmed and painted. Externally, the walls were treated with the coloured, lightweight and waterproof render, Monocouche. Finally, the roof trusses were overlaid with plywood, with an artificial slate covering.

Installation of large steel security doors and frames, designed specifically for substations, demanded high levels of precision. We had to ensure that the structural openings were near millimetre-perfect to the supplied dimensions: there was no room for error. As we completed the final fit of Kee Klamp handrails around the perimeter of the control building, a new access road was being laid.

This allowed the cranes and articulated lorries bringing huge sections of turbine (transported by boat from Holland to Newhaven) to access the site. As those lorries rolled in, the client was highly satisfied with the significant role that Hawes Building had played in ensuring that the entire contract was completed on time.

Hawes Building

THE BENEFITS

Specialist expertise across a range of disciplines enabled Hawes Building to construct the complex electrical control building that is central to this large civils project undertaken by Knights Brown Limited.

The three-turbine wind farm has the capacity to provide the community with 7460.00(kW) of wind power.

Our flexibility and commitment to meet shifting deadlines meant the entire project was delivered by the due date.

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