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Norfolk biomass plant

Name of fabricator: Caunton Engineering
Galvanized by: Joseph Ash Galvanizing
Architect and structural engineers: Ramboll
End client: The project was funded by two Scandinavian organisations, Burmeister & Wain Scandinavian Contractor (BWSC) and PensionDanmark
Finish provided: Hot dip galvanizing
Size and amount of steel: 1500 tonnes

Project goals
In 2017 a new energy plant opened in Norfolk, with an electrical capacity of 44.2MW and the ability to supply 82,000 homes with energy.

It was an interesting project as the energy is generated from burning organic matter. Local farmers also play a part as they supply (and make an income from) the 250,000 tonnes of straw and woodchip used to generate the energy.

Ramboll, Caunton Engineering and Joseph Ash Galvanizing were called in to help with the project.

What happened
Caunton Engineering fabricated steel for the following elements:

  • Stairs
  • Platforms
  • Two barns for straw
  • The roof of the woodchip barn
  • Crane beams
  • Boiler house
  • Turbine hall.

They engaged Joseph Ash Galvanizing to treat the steel with a hot dip galvanized coating to protect it from the elements for many years to come.

Gary Hatton of Caunton Engineering said that they chose Joseph Ash Galvanizing because of our ability to turnaround the high tonnages of a complex galvanized frame to programme in accordance with the required Quality Assurance.

Materials and size
Over 1500 tonnes of steel was fabricated and hot dip galvanized. It was a huge job as the steel beams for the turbine hall alone were 33m long and 8 tonnes in weight each.

The building is a large braced frame with cross bracing inserted between the main columns, which are spaced at 5.7m intervals.

Biomass energy in Norfolk NR13 3 is becoming an increasingly popular choice for providing an alternative fuel source to traditional gas and coal solutions. The need to try and steer our dependency away from fossil fuels towards a cleaner, more environmentally friendly source has never been more of a priority than it is now.  

Steven Hopkins, Managing Director at Joseph Ash Galvanizing said:

“This is exactly the sort of project that we like to be involved in, offering an opportunity for careful planning well in advance to ensure that the steel components are designed and fabricated to take into account the hot dip galvanizing process. This promotes the best possible quality of finish with minimum waste and less of an environmental impact. Demanding jobs like this bring out the best in us, in order to achieve total customer and end-user satisfaction. The experience gained then benefits our entire customer base.”

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Name of fabricator: REIDsteel
Galvanized by: Joseph Ash Medway
Architect: Arete Architects
Contractor: FM Conway
End client: Maidstone United FC
Finish provided: Hot dip galvanizing and powder coating
Size and amount of steel: 100 metres of steel railings and gates

Project goals
Maidstone United FC needed to increase its seating capacity for fans at its home – the Gallagher Stadium – as it moved up the league charts. The club made the decision to build a new stand, and they turned to Arete Architects and REIDsteel for help with design and construction.

What happened
REIDsteel worked directly with Maidstone United FC to design, draw, fabricate and erect a new £850,000 structure at the Gallagher Stadium – including steelwork, cladding, 500m of handrails and disabled access ramps.

To protect their steel fabrications with a variety of metal finishing treatments, predominantly hot dip galvanizing, they called on the expert services of Joseph Ash Galvanizing’s Chesterfield plant.

Materials and size
The steel-framed standing terrace was built behind one of the goals. It consists of 11 double standing rows, formed with non-slip metal decking supported by a series of steel rakers. The stand has a 11m-wide cantilevering steel roof structure, which includes a 1m-high facia for advertising. It also includes 500m of handrails and disabled access ramps.

The structure includes 81 tonnes of steel, all fully hot dip galvanized by Joseph Ash Galvanizing.

The new North Stand was successfully completed in March 2017 and was opened in front of a crowd of 2,929 people. The new stand provides the stadium with an extra 1768 seats for ticketholders.

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Name of fabricator: REIDsteel
Galvanized by: Joseph Ash Galvanizing
Contractors: Tata SteelNational Tube Stockholders, EurocladAyrshire Metal ProductsBAPPPowell Gee & Co LtdKestrel Liner AgenciesMeachers Global Logistics and Newton Construction Co Ltd
End client: Enis Adams Primary School
Finish provided: Hot dip galvanizing

Project goals
The Enis Adams Primary School in the British Virgin Islands was destroyed by Hurricanes Irma and Maria in 2017. To help the island and the school community, Dorset based John Reid & Sons Ltd (REIDsteel) led a consortium of businesses in the UK to help rebuild the school. The company, which has exported to the Caribbean for more than 30 years, rallied its suppliers to provide support free of charge, in kind or at a discounted rate to the total value of £35,000.

Joseph Ash Galvanizing was happy to help.

What happened
REIDsteel – whose specialities include disaster-resistant buildings – designed and manufactured the steelwork for the new school to withstand any future hurricanes and to give something back to the islands.

REIDsteel provided design and manufacturing services on a not for profit basis worth over £30,000.

In total, seven 40’ cargo containers full of steel work were shipped across the Atlantic for the project on the island of Tortola.

Tata Steel helped with the supply of ComFlor® floor decking and provided Colorcoat® pre-finished steel including Colorcoat Prisma®, whilst Cardiff based Euroclad gave finished roof systems.

Thirsk-based National Tube Stockholders gave steel tube and steel hollow sections.

Joseph Ash Galvanizing hot dip galvanized the structural steelwork and Ayrshire Metal Products gave secondary steel – cold rolled purlins.

Barnsley-based BAPP supplied industrial fasteners and bolts, Powell Gee of Shrewsbury supplied fixings for floor decking and the external cladding envelope.

Kestrel Liner Agencies, a global Caribbean shipping specialist which offers weekly sailings from more than 145 ports to the Caribbean basin, helped with shipment and Meachers Global Logistics with shipping services.

Much to the delight of the pupils, teachers and islanders, the new school opened in 2019.

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