NORTH BLYTH BIOMASS PROJECT

THE PROPOSED NORTH BLYTH BIOMASS POWER STATION

ORDER

APFP Regulation: 5(2)(a)

Document Title: Preliminary Outline Method Statement Intake

Structure
(Appendix 4.2 of Environmental Statement)
Date: February 2012
Author: Fairhurst Ltd
Document Number: 6.2.08

Document Ref: 02377-001224 Issue: 02

Revision History
Document Title: Preliminary Outline Method Statement Intake
Structure
(Appendix 4.2 of Environmental Statement)
Revision

Date

Author

01

February 2012

Fairhurst Ltd

Document Ref: 02377-001224 Issue: 02

RES
North Blyth Renewable
Energy Plant
D/I/D/81354/101

Preliminary Outline Method

Statement Intake Structure

February 2012

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North Blyth Renewable Energy Plant

D/I/D/81354/101

CONTROL SHEET

CLIENT:

RES

PROJECT TITLE:

North Blyth Renewable Energy Plant

REPORT TITLE:

Preliminary Outline Method Statement Intake

Structure

PROJECT REFERENCE:

81354

Issue and Approval Schedule:

ISSUE 1

Name

Signature

Date

DRAFT
Prepared by

A Lowes

Reviewed by

D Ladkin

Approved by

D Ladkin

Revision Record:
Issue

Date

Status

Description

25/07/11

Information

Minor Amendments

7/09/11

Information

Minor Amendments

2/02/12

Information

Minor Amendments

By

LT

Chk

AJL

App

AJL

This report has been prepared in accordance with procedure OP/P02 of Fairhursts
Quality Assurance System.

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CONTENTS
1.0

INTRODUCTION ......................................................................................................... 1

2.0

LOCATION OF WORKS ............................................................................................. 1

3.0

FORM OF STRUCTURE ............................................................................................ 1

4.0

EXPECTED GEOTECHNICAL AND HYDROLOGICAL CONDITIONS..................... 1

5.0

TECHNICAL CONSTRAINTS TO BE OVERCOME................................................... 2

6.0

POTENTIAL METHODS OF CONSTRUCTION ......................................................... 2

7.0

SEQUENCE OF CONSTRUCTION ............................................................................ 4

APPENDIX A

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DRAWINGS

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D/I/D/81354/101

1.0

INTRODUCTION
As part of the proposal to develop a Biomass Power Station at Battleship Wharf, Port
of Blyth, it will be necessary to construct a cooling water system with an intake
abstracting water from the River Blyth. The intake structure will be located to the rear
of the retaining wall, on the land-ward side of the existing Quay 4.
This preliminary outline method statement discusses the potential methods and
sequence of construction for this structure based upon outline design information
supplied by SKM, available geotechnical and hydrological information for the area and
constraints imposed by constructing the intake within an operational port.
This method statement has been prepared to discuss the technical procedures and
sequence of works for the installation of the intake structure. Health, safety and
environmental requirements, design and construction quality assurance procedures,
regulatory liaison and liaison with third parties are not included in this method
statement.

2.0

LOCATION OF WORKS
The preferred location for the intake structure is to the rear of the existing retaining wall
at the southern end of Quay 4 at Battleship Wharf. As the intake is on the landward
side of the existing cofferdam river wall no construction activity will take place within
the River Blyth Estuary, other than when the existing cofferdam and sheet pile river
wall are broken through for the installation of the header pipe work.
The intake structure will extend from the retaining wall to close to the south western
corner of the Bulk Shed 2. The area in which the intake structure will be located is
currently utilised as a hardstanding area with a circulation road running north south
through it. It is understood that the existing quay retaining wall is restrained by high
level ground anchors.

3.0

FORM OF STRUCTURE
The preliminary general arrangement of the intake structure is shown on sketch
drawing dated 9th February 2010, Appendix A. It will comprise a chambered reinforced
concrete structure with a reinforced concrete cover slab designed to allow the
trafficking or port vehicles and plant over it. The section of the structure that is nearest
to the river will consist of a settling chamber. The central section will contain a band
screen. The inland section will consist of a dry well pump chamber and a
manifold/valve pit. Water will be drawn into the intake via a transverse slotted pipe
intake suspended below the deck of Quay 4. The pipe will penetrate through the
existing retaining wall.
It is understood, from the information presented in the desk study provided in
Appendix 15.1 of the accompanying Environmental Statement, that the required
excavation depth for the construction of the intake is approximately -7.5mOD and that
the overall width of the structure will be approximately 9m.

4.0

EXPECTED GEOTECHNICAL AND HYDROLOGICAL CONDITIONS

Based upon historical site investigation information, presented in the desk study
provided in Appendix 15.1 of the accompanying Environmental Statement, the
following approximate geotechnical sequence can be expected at the proposed
location for the intake structure.

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Elevation

Description

+4.00m - +3.50m OD

Port hardstand pavement construction

+3.50m - -2.75m to - Heterogeneous granular made ground consisting of sand,

4.5mOD
gravel including mudstone, demolition arisings and ash
overlying natural wind blown loose sand
Below -2.75mOD to - Middle Coal Measures consisting of sandstone overlying
4.5mOD
mudstone and coal.
The tidal range in the River Blyth is:

5.0

Highest recorded

+3.61m OD

Mean High Water Springs

+2.44m OD

Mean Low Water Springs

-1.88m OD

Lowest Recorded

-3.61m OD

TECHNICAL CONSTRAINTS
To construct the intake the following technical challenges must be considered in the
design of the temporary and permanent works and construction methodology.

6.0

1.

Significant temporary works required to construct through heterogeneous and

loose soils overlying rock.

2.

Maintaining a dry working area adjacent to a river with a large tidal range which is
significantly above the proposed excavation depth.

3.

Minimising impact on port operations throughout construction.

POTENTIAL METHODS OF CONSTRUCTION

There are three potential method of construction for this structure:

6.1

1.

Construct intake structure within cofferdam constructed as a steel combi wall

spigotted into the bedrock with rock excavation below rockhead.

2.

Construct intake structure within a cofferdam constructed from concrete

diaphragm walls. The diaphragm walls would form the external walls of the
permanent structure.

3.

Construct intake structure within a cofferdam constructed from concrete secant

pile walls. The secant pile walls would form the external walls of the permanent
structure.

Cofferdam Constructed as a Steel Combi Wall

A conventional sheet pile wall would not penetrate into the bedrock sufficiently to
provide toe restraint. To avoid the requirement to install a low level prop at rockhead, a
modified form of sheet pile wall, a combi wall, which uses both steel tubes and sheet
piles to form the wall could be used. The tubes would be driven to refusal into the rock
and cored out. A spigot consisting of a steel dowel driven into the rock and restrained
by a concrete plug would be installed into the bottom of the tubes. Up to three sheet
piles would be installed as infill panels between the tubes. It is anticipated that a high
level prop would be required to maintain stability.
Below rockhead excavation would be carried out directly through the bedrock with the
cut face of the rock forming the extent of the excavation. It is anticipated that the

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sandstone would be strong enough to form a near vertical face, however, if mudstone
layers are encountered temporary shoring of the face using sprayed concrete may be
required.
On completion of the excavation the intake structure would be constructed. The
sequence of construction would require careful integration with the temporary works
design to ensure that when temporary props are removed the partially constructed
intake structure has sufficient stiffness to resist the lateral earth pressure loads
previously resisted by the props.
There are significant disadvantages with this form of cofferdam installed where the
bedrock horizon is higher than the base of the excavation:

6.2

It is difficult to waterproof sheet pile and combi walls and as such seepages
through the clutches and at the wall bedrock interface should be expected.

If mudstone layers are encountered the excavation face should be supported and
protected with sprayed concrete.

Unless the sheet piles or combi wall is designed to form part of the structure the
temporary works will have to be removed on completion of the structure

Cofferdam Constructed As A Diaphragm Wall

In this form of construction a trench is excavated and usually supported by bentonite.
When the trench reaches the design depth concrete is poured into it which displaces
the bentonite. On completion of the pour a reinforcement cage is inserted. After the
wall has been constructed the central area can be excavated and the base slab and
internal compartment walls can be constructed.
Due to the depth of the chamber required it is considered that as a minimum a
temporary high level internal prop will be required to minimise the thickness of the
diaphragm wall.
The advantage of this form of construction are

The permanent works are also used as the temporary works.

Seepages through the base the excavation can be controlled by sump pumping
and general groundwater lowering will not be required.

The reinforcement cages can easily be designed so that couplers project from the
face of the wall to allow the connection of the reinforcement for the transverse
walls without breaking out concrete.

The diaphragm wall will have a rough surface from being cast against the ground,
however this could easily be prepared, if required, to improve the hydraulic
performance of the structure.

The disadvantages of this form of construction are:

The installation requires the preparation and handling of large volumes of

bentonite slurry which would have an adverse impact on the river if a spillage or
seepage occurred. During concreting of the walls the displaced benonite would
have to be carefully contained and stored prior to disposal.

The bentonite would have to be disposed of as waste.

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6.3

Cofferdam Constructed As A Secant Pile Wall

An alternative form of top down construction to a diaphragm wall would be to construct
the external walls using overlapping piles. This form of wall construction is known as a
secant pile wall. After the piles have been constructed the intake chamber would be
excavated and constructed to the same method as the diaphragm wall solution.
The advantages of this solution are:

There would be less likelihood of requiring the use of bentonite in the process.

The permanent works are also used as the temporary works.

Seepages through the base the excavation can be controlled by sump pumping
and general groundwater lowering will not be required.

The disadvantage of this solution are;

6.4

The internal face of the wall will be a series of interlocking piles with a rough
surface as the concrete was cast against the ground. This may not deliver the
required hydraulic performance required for the structure and an internal nonstructural facing of concrete may be required.

It is very difficult to install a reinforcement cage so that couplers are correctly

located at the face of a pile. As such, to form the tie between the external wall
and internal walls extensive breaking out and drilling into the piles will be
required.

Preferred Form of Construction

The most practical form of construction for the intake would be top down construction
using diaphragm walls. With this form of construction the excavation and construction
of the internal walls of the intake can be constructed within a robust watertight
cofferdam which then forms part of the permanent works. The drawback of this method
of construction is that it will require the use of bentonite close to a controlled water. As
such, rigorous surface run-off control measures to prevent bentonite entering the river
will have to be designed, agreed with the Environment Agency and implemented.

7.0

SEQUENCE OF CONSTRUCTION
The sequence of construction outlined below is based upon the construction of the
intake within a cofferdam constructed from diaphragm walls. The schematic
arrangement of the works is shown on Drawings 81354/SK003 and 81354/SK005,
Appendix A.
1.

Agree with the Port of Blyth and implement a traffic management system to allow
port operations to continue around the work area.

2.

Carry out trial trenching to locate ground anchors restraining existing quay
retaining wall. Where anchors clash with location of intake, agree relocation of
anchors with Port of Blyth.

3.

Agree with Environment Agency mitigation measures required for batching,

handling and disposing of bentonite. Works to be carried out in accordance with
Environmental Permitting Regulations and a Construction Quality Assurance
Plan.

4.

Excavate trenches to design depth under bentonite support.

5.

Place concrete and reinforcement. Contain and dispose of displaced bentonite.

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6.

After diaphragm walls have cured sufficiently, excavate to design formation level.
Install props as required by the temporary works design.

7.

Construct internal walls, remove props when required by the temporary works
design.

8.

Install intake header below existing quay.

9.

Break through riverward wall and install header pipework into wall. The
dimensions of the break through will be dictated by the mechanical design of the
cooling water system, however it is anticipated that a break through for a pipe 1
to 2m diameter will be required.
There is only a risk of construction materials / demolition arisings falling into the
intertidal mudflats during breaking through of the quay wall. Prior to this activity
taking place, netting will be erected to contain falling materials. The break
through will be designed so that saw cutting / coring through the wall will be
utilised to allow materials to be removed in sections rather than broken up in situ
using hydraulic breakers.

10.

Install plant and commission. Remove traffic management system.

The final timescale will be determined during detailed engineering design of the works,
though it is recommended that works on the wall and river side of the wall will be
undertaken during the summer months to avoid impacting upon over wintering birds.

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APPENDIX A
DRAWINGS

February 2011

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