SIXEP Continuity Plant – Precast Beam Supply for Sellafield, Cumbria

SIXEP Continuity Plant – Precast Beam Supply for Sellafield, Cumbria

Client

Client: Sellafield Limited
Main Contractor: Carey Group
Sector: Nuclear infrastructure and civil engineering

Project Overview

The SIXEP Continuity Plant at Sellafield, Cumbria, is a crucial upgrade to Europe’s largest and most diverse nuclear energy site. This facility is designed to continue the safe and efficient treatment of radioactive effluent, supporting the site’s ongoing operations and decommissioning activities. The new plant features advanced process and service buildings, constructed to the highest standards of safety, quality, and precision.

Key Project Details:
• Supply of bespoke precast beams for the multi-bay precast concrete top floor structure
• Integration into a complex, high-specification nuclear facility
• Collaboration with the main contractor and project team to meet demanding programme requirements

The Client’s Challenge

Specific Problem:
The construction of the SIXEP Continuity Plant required the installation of a multi-bay precast concrete roof structure, involving dozens of beam variants. The project demanded millimetre accuracy to accommodate a dense array of mechanical and structural elements, all within the strict regulatory framework of a live nuclear site.

Why Resolution Was Critical:
• Ensured the structural integrity and safety of the new process and service buildings
• Supported timely project delivery to control costs and enable seamless handover to process contractors
• Maintained compliance with nuclear sector quality and safety standards

Risks if Unresolved:
• Delays to the commissioning of the new effluent treatment facility
• Increased project costs and potential disruption to site operations
• Compromised safety or non-compliance with regulatory requirements

Solution

ABM Precast Solutions supplied the full range of bespoke precast beams required for the top floor structure of the SIXEP Continuity Plant. Our approach focused on precision, reliability, and close coordination with the main contractor and project stakeholders.

• Manufactured and delivered multiple variants of precast beams to exacting tolerances
• Supported just-in-time delivery and site logistics to align with the project’s complex installation sequence
• Ensured all beams were fully compliant with stringent nuclear sector specifications
• Provided technical support and documentation to facilitate seamless integration with the contractor’s digital construction and quality management systems

Technical and Logistical Innovations:
• Precision casting and quality assurance to meet millimetre accuracy requirements
• Flexibility to accommodate evolving site needs and installation schedules

The Results

Outcomes for the Client:
• Successful installation of all precast beams as part of the multi-bay roof structure
• On-time delivery to support the project’s critical path
• Contributed to the achievement of key programme milestones and quality benchmarks

Quantifiable Results:
• All precast beams delivered and installed to specification
• Supported completion of the top floor slab ahead of schedule

Key Takeaways & Summary

The SIXEP Continuity Plant project demonstrates ABM Precast Solutions’ capability to deliver precision-engineered precast beams for complex, safety-critical nuclear infrastructure. Our contribution supported the successful delivery of a facility essential to the long-term operation and decommissioning of Sellafield.

Benefits Delivered:
• High-quality, precision-manufactured precast beams for a demanding nuclear environment
• Reliable, on-time supply supporting a challenging construction programme
• Proven expertise in collaborating on major, regulated infrastructure projects

Unique Selling Points:
• Technical excellence in precast beam design and manufacture
• Experience in nuclear and high-specification infrastructure
• Commitment to client satisfaction and project success