Replacement Ducting Phase 1
Client: British Gypsum
Location: Sherburn in Elmet
Industry: Gypsum Production
Project Overview
Full design, fabrication, delivery, and installation of a new milling and calcining system. The upgraded system is capable of processing natural gypsum, desulphogypsum (DSG), and reclaimed materials, integrating seamlessly with existing plant infrastructure to enhance production efficiency and material handling capabilities
Scope of Work
The scope of works comprised Operating as principal contractor overseeing all the work phases from civils to commissioning, mechanical installation, detailed structural design, and the fabrication and supply of all associated steelwork.
Our team executed a fully designed solution, developing the steelwork model in Tekla Structures to achieve interface tolerances compatible with the GEBR Pfeiffer processing equipment. This precision was essential due to the requirement to integrate the design loas of 300 tonnes of process equipment, ducting, and support systems.
Steel works supplied fully complaint with 1090 Execution Class 2
The package further incorporated installation of the external cladding system, ductwork insulation with integrated trace heating, construction of the MCC room, and all ancillary mechanical and structural elements necessary to deliver a fully integrated plant installation
Challenges Faced
The works were undertaken within a highly constrained and compact site footprint, adjacent to a live 365-day production facility. This environment imposed strict limitations on access, craneage, material laydown, and sequencing, while requiring continuous coordination to avoid disruption to ongoing plant operations.
Technical execution also demanded precision despite the time pressure, with critical alignments, torqueing, tolerances and measurements needing to be completed accurately while relying on specialised tools and OEM parts that could cause delays if missing or faulty. These challenges were compounded by the financial impact of downtime, where every hour of shutdown represented substantial production loss, creating tension between fast turnaround and quality workmanship. Additionally, long hours and compressed schedules contributed to workforce fatigue, increasing the risk of errors and underscoring the importance of careful management and control throughout the shutdown.
Solutions Delivered
To mitigate these constraints, the project team implemented rigorous programme and interface management, supported by phased logistics planning and controlled delivery schedules. Extensive off-site preassembly was utilised to reduce time on site, minimise lifting operations, and improve installation accuracy, ensuring safe and efficient execution within the operational facility.
When unexpected issues surfaced, we didn’t hesitate; we adapted, solved problems on the spot and kept the shutdown moving forward. Whether it meant taking on additional tasks, reorganising teams or working extended hours, we did what needed to be done to ensure the job was finished safely, efficiently and to a high standard.
In the end, it was Don Valley’s determination, teamwork and unwavering attitude that turned a difficult shutdown into a successful outcome.
Outcome
The successful completion of the project enabled the facility to fully process and produce gypsum, ensuring uninterrupted production capability. The precise installation of steelwork and associated mechanical systems allowed seamless integration with existing operations, meeting both performance and safety requirements