Mabey Hire was engaged by Foundation Solutions HV Ltd to design and supply formwork for the construction of the new-build Benbrack Substation in Dumfries & Galloway for SPEN. Here, Ryan Smillie (design team leader, Mabey Hire); Jack Griston (engineering technician, Mabey Hire); and Calvin McPhee (operations director, Foundation Solutions) tell Project Scotland about the major project.
Can you provide a general overview of the project?
Ryan: The project involved over 100 cast in-situ concrete structures, each with varying dimensions and pour heights. These included a 33kV switchgear building, transformer bund, CCTV camera bases, and foundations for security fencing. Jack Griston served as the sole engineering point of contact for Mabey Hire, coordinating closely with internal teams and Foundation Solutions HV Ltd. throughout the entire project lifecycle, from the pre-construction phase to the successful completion of works on site.
What was Mabey Hire’s role in the works?
Ryan: Mabey Hire’s role involved close collaboration with the contractor to review the project timeline and develop tailored formwork solutions for each structure. Jack’s ongoing communication and coordination with the site teams was essential in building trusted relationships and gaining a comprehensive understanding of the construction phases and project challenges.
The design solutions encompassed a variety of configurations, including slab edges, double-sided, and single-sided arrangements, specifically designed to meet the diverse requirements of the project. Upon confirmation of the design, this allowed us to effectively coordinate with our operations team to supply all necessary formwork shuttering.
Why did you opt to use the lightweight panel system? What are the benefits of this system?
Jack: Our lightweight panel system is well-suited for this type of project, as it can be easily handled with a maximum component weight of under 50kg. The versatility of the system allows for the reuse of equipment across various applications.
From a sustainability perspective, this significantly reduced transportation to the remote site, thereby lowering the overall carbon footprint and aligning with our internal ESG strategy. We were able to utilise a single, universal set of equipment to complete all concrete pours efficiently.
What were some of the biggest challenges and how were they overcome?
Jack: One of the most significant design challenges we encountered was the restricted working space. The close proximity of the concrete structures and complex ducting limited both the range of solutions and the positioning of props. As a result, we had to develop custom designs and calculations beyond the scope of our standard product user guide and technical documentation.
Additionally, changes in the site schedule required the re-design of certain pours, with the key challenge being the efficient use of equipment already on site to minimise the need for further deliveries, whilst working to strict time constraints.
Did you learn anything from the project that you can take into future schemes?
Ryan: A key takeaway from the project was the importance of maintaining consistent communication with the site teams and fostering a trusted relationship. Having Jack as a singular engineering point of contact enabled us to refine and align our internal processes, ensuring the delivery of an exceptional customer experience.
The bespoke design elements developed during the project can be applied to future schemes, enhancing both efficiency and cost-effectiveness.
Is this a sector you envisage Mabey Hire becoming more involved in?
Ryan: Yes, we envision Mabey Hire becoming more involved in the energy sector. We are currently working closely with key contractors, including Foundations Solutions HV Ltd., to support this market and help deliver projects more efficiently. Our extensive product range, which includes solutions for site access, monitoring, bridging, formwork, groundworks, and propping, positions us uniquely to meet the diverse needs of energy sector projects.
Leveraging our existing experience and capabilities, along with local engineering support, we are a trusted partner in this sector, contributing to sustainable energy solutions while continuing to deliver exceptional service and innovation. As the energy landscape evolves, we remain committed to adapting our offerings to meet the industry’s needs and drive progress in future projects.
What feedback did you receive from the contractor following the project’s completion?
Calvin: Mabey Hire were excellent to deal with as a temporary works supplier and designer. From meetings at pre-construction stage of the project in FSHV’s office running through each design type individually, to ongoing support and dialogue with our project team throughout. We would highly recommend Mabey Hire and will continue to use them for our temporary works needs in the future.
