Hinkley Point C

Cleaner, Brighter Future in the UK with Formwork Construction

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United Kingdom Construction

As countries worldwide are adopting environmental policies, the United Kingdom has pledged to reach net-zero carbon emissions by 2050 and is striving to achieve this goal through the construction of Hinkley Point C. This is the first new nuclear power station to be built in the UK in over 20 years. EFCO has partnered with Kilnbridge on the inlet and outfall structures of this massive concrete construction project that began in 2018, with the plant set to be fully operational in 2026.

Providing electricity for 6 million homes

Net-Zero Carbon Emission for Nuclear Power Station

With a lifespan of 60 years, the output of the two EPR reactors will offset 9.9 million tons of carbon dioxide emissions per year or 660 million tons over its lifespan. The power stations will provide zero-carbon electricity for six million homes in the United Kingdom.

Increasing Economic Growth in the United Kingdom

Construction of Hinkley Point C

The construction of Hinkley Point C has had a significant impact on the United Kingdom economy, employing an estimated 22,000 workers and 800 apprentices. So far, £123 million has been invested into the community, with 64% of the project’s construction value predicted to go to UK companies.

Formwork and Shoring Provider with Experience

EFCO United Kingdom

EFCO UK stepped in as an experienced concrete formwork and shoring partner for Kilnbridge on the marine package. EFCO has been providing formwork solutions and onsite support to create structures totaling 10,000 cubic meters of concrete poured at the Avonmouth site.

Marine Formwork Construction | Hinkley Point C

Falsework for Concrete Construction

The inlet and outfall heads being constructed at Avonmouth Docks are part of the structure that provides cooling water to the primary nuclear facility location. These structures will eventually be rolled onto barges and taken to an area off the coast of the main site in Somerset, Southwest England, where they will be lowered onto the seabed to regulate the flow of cooling seawater.

Under the Sea Tunnel Construction

23’ Diameter Tunnels

The four inlet and two outfall tunnels are being constructed now under the sea. The heads will connect to the end of the 23’ diameter tunnels and funnel seawater to two nuclear reactors. With each head weighing up to 6,065 tons and a projected 60-year lifespan on the seabed, the process for construction and tolerances are at Class 1 nuclear level which is rarely seen in the UK construction industry. 

Quality of Concrete Critical for Class 1 Nuclear Structure

Formwork With No Ties

The concrete inlet and outfall heads are subject to a challenging environment. Any defect in the concrete can cause seawater to reach and degrade the rebar causing the structure to fail and not perform to the required parameters. Thus, forming concrete structures without any tie locations and with minimal construction joints was deemed critical to their performance and life span and to meet their Class 1 nuclear specifications.

Formwork Solution for Cone-Shaped Shaft

EFCO Steel ***PLATE GIRDER*, REDI-RADIUS and SUPER STUD**

EFCO UK has provided over 23,680 ft² (330 tons) of PLATE GIDER®, REDI-RADIUS®, and SUPER STUD® forms for the project, including custom transition cone-shaped formwork for the central shafts. The PLATE GIRDER system was the ideal system to use as it has the strength and capability to be tieless. The challenge was to design the formwork to support the weight of the cast concrete without any internal ties that could potentially weaken the structure.

Formwork to Build a Shaft

The SUPER STUD Solution

EFCO provided a formwork solution that combined ring compression and internal bracing to restrain the shaft and void formers, which externally anchors SUPER STUD® A-frames, and bracing. This approach eliminated the need for through ties in the formwork.

The entire project team sees that health and safety culture and performance are key contributors to achieving engineering excellence and the world-class quality standards required on these Class 1 nuclear structures. Our supply chain members’ active involvement and buy-in are essential to realizing this goal. The EFCO Management Team and field engineering support on this project has ensured that this high bar is a realistic target that can be met safely and efficiently.

-Rick Kopec, Kilnbridge Construction
Contracts Manager

EFCO Formwork for Bridge Columns and Bridge Caps | SUPER PLATE GIRDER