Energy

The wind farm projects we have completed across the United Kingdom account for 5% of the UK’s total onshore wind energy.

We have carried out projects ranging from single foundations to the full balance of plant for a 22 turbine scheme and onshore works for off-shore wind farms.

Our project management team can deliver anywhere in the UK, regardless of project size, providing customers with continuity of approach and clear lines of communication that build strong working relationships.

Our capability is expanding beyond wind into a broader range of energy sectors including tidal, solar, peak demand, energy from waste, energy storage and anaerobic digestion.

Double Arches Wind Turbine
Double Arches Wind Turbine

Double Arches & Quarrendon Fields

Double Arches Wind Turbine
Customer: Vensys Energy AG
Value: £318k

Raymond Brown was awarded the contract for the design and construction of a Vensys V87, 100m Hub Height, 1.5MW piled turbine foundation for Vensys AG. This is one of three schemes that we have constructed for the customer, who are currently expanding their UK wind market. The Vensys V87 constructed at Double Arches currently stands as the tallest wind turbine within the UK to date with a 100m hub height and tip height of 145m.

The project was constructed within a tight programme deadline. The customer's main criteria was to ensure that the turbine was commissioned and energised by the FITs deadline in December 2014. Raymond Brown worked collaboratively with numerous third parties as Principal Contractor to ensure everything ran smoothly and safely.

The turbine foundation piling comprised 60, 400mm x 400mm precast concrete square piles installed to a depth of 19m in two concentric circles.

The turbine foundation itself consisted of 550m³ of concrete and 70t of steel reinforcement. Our management team worked closely with our supply chain to ensure the large concrete pour was successfully completed in one 12 hour period with minimal impact on the local community and highway network.

The site was accessed off the A5 highway, so traffic management was utilised to mitigate interface with members of the public. The site was also accessed through a live Aggregate Industries sand quarry. As a result of this we were required to ensure that we liaised and adhered to the safety rules of the quarry to ensure minimum disruption and maximum safety.

The piling mat was designed and constructed using recycled aggregates, which was reused at the end of the project. The recycled aggregate meant a saving to the customer and a reduced carbon footprint for the scheme.
Garlenick Wind Farm
Garlenick Wind Farm

Garlenick Wind Farm

Garlenick Wind Farm
Customer: Airvolution
Value: £1.1m

Raymond Brown was awarded the balance of plant contract to construct two Vestas V90s at Garlenick Wind Farm in Cornwall. The turbines are 110m high to the tip of the blade and are expected to produce enough electricity annually to power around 2,400 households.

This scheme sits alongside two other projects that Raymond Brown has undertaken constructing for Airvolution; East Youlstone Wind Farm which is a balance of plant for two Vestas V80s and Daintree Wind Farm a balance of plant for two Vestas V90s.
Delta Stream Offshore Turbine
Delta Stream Offshore

Delta Stream Offshore Turbine

Delta Stream Offshore Turbine
Customer: Delta Stream Civils
Value: £75k

Tidal Energy has installed the first Delta Stream turbine off the coast of Pembrokeshire at Ramsey Sound. The turbine is the first consented test site in Wales and will be used as a pilot to provide evidence of the efficiency of the device for producing tidal energy before being rolled out across future projects.

Raymond Brown Construction was awarded the balance of plant contract for the onshore works required to connect the device to the mainland. The works included the construction of a temporary power conversion compound, road and foundation construction, fencing and conduit/ducting. We also carried out the electrical works including electrical cabling, shoreline jointing connections and communication routing between the shore and compound.
Ferndale Wind Farm
Ferndale Wind Farm

Ferndale Wind Farm

Ferndale Windfarm
Customer: Infinergy Ltd/Wind Assets Ltd
Value: £1.53m

Raymond Brown Construction was appointed to undertake the civil engineering works for the eight turbine wind farm at Ferndale. The scheme has a total installed capacity of 6.4 MW, enough to produce the annual electricity demands of 3,500 households every year (calculation based on industry standard - RenewableUK).

The scope of works included the upgrade of 1.5 km of existing Forestry Commission tracks, the design and construction of 2.2 km new tracks of 4.5 metres width, some of which were floated track on deep peat, large areas of cut and fill, the underground cabling to the control building and to turbine locations and the design and construction of new substation.
Enercon Framework Cluster
Enercon Framework Cluster

Enercon Framework Cluster

Enercon Framework Cluster
Customer: Enercon
Value: Various

Raymond Brown has continued their excellent working relationship with Enercon since it started in 2009 with the construction of framework foundation projects. These projects comprise single E48 turbine foundations projects and multiple foundations of various types.

Each project requires a different approach as there are a large number of Enercon foundation designs that can be implemented and some contain site specific design such as piles or soil replacement. The types of foundation we have constructed under the framework are:

• E33
• E48
• E53
• E70
• E82

One of our management strengths on these framework projects is our ability to procure all necessary materials and our coverage, which allows us to construct anywhere in the UK.

During the construction of the various types of foundations we included additional site specific activities such as pile cropping, load ring installation and tower section grouting. These elements are required to achieve the best possible results in terms of programme goals and overall project success.

Over the last six years we have completed 185 wind turbine foundations on a large number of projects including:

• Greenside - 4 x E70 with piles
• Lochelbank - 12 x E53
• Hillhead of Auquhirie - 3 x E70
• Skilmafilly - 3 x E70
• Newton of Fortrie - 3 x E70
• Marston Vale - 1 x E70 (constructed in a country park)
Wear Point Wind Farm
Wear Point Wind Farm

Wear Point Wind Farm

Wear Point Wind Farm
Customer: Wear Point Wind Ltd
Value: £1.8m

SemLogistic, Milford Haven, is one of the largest storage and distribution facilities of petrochemicals in the UK. It was on this site that we were contracted to deliver a balance of plant contract associated with the development of a 4 REpower MM82 (8.2 MW) wind farm at Wear Point.

The works included the design and build of WTG foundations, site tracks, crane pads, 33kV electrical connection with substation, inter turbine array cabling, and a single span concrete beam road bridge.

The turbine location was enclosed on two sides by steel pipes that transport aviation fuel from the deep water jetties to one of the many steel storage tanks, a liquefied natural gas plant, and the coast on the two other sides.

The solution proposed was to construct a reinforced concrete access bridge that spanned over the petrochemical pipes.

The design brief for the bridge was:

- Enable permanent access to T1
- Satisfy maximum track gradients; max longitudinal 7%, cross fall 3%
- Swept path and weight requirements of abnormal HGV delivery vehicles
- Maintain a minimum clearance between pipes and bridge deck (300mm)

The bridge was positioned at a location that minimised the earthworks to the adjacent embankments and to suit the local geology. This was concluded after undertaking a topographic GPS survey of the proposed locations. The bridge was constructed at 45 degrees to the adjacent road due to the restriction of adjacent petrochemical pipes.

Bridge facts:
- Bridge span 12m
- Bridge width 14.9m
- Total steel 23.2 ton
- Total concrete poured in bridge 271m3
Newton Marsh Wind Farm
Newton Marsh Wind Farm

Newton Marsh Wind Farm

Newton Marsh Wind Farm
Customer:Anglian Water Services
Value: £450k

Raymond Brown was awarded the Balance of Plant contract to construct two Enercon E70 turbine developments for Anglian Water as part of a wind farm framework on their existing treatment works.

Newton Marsh was constructed on the grounds of an operational waste water treatment facility with several conservation areas requiring implementation of specialist construction methodologies which was overseen by an Ecological Clerk of Works.

The project involved the design and construction of civil engineering works, including modifications to the site entrance, new tracks, site compound and crane hardstanding. We also designed a piled solution that combined with the foundation design supplied by Enercon for the site.

Electrical works included HV and LV systems and communications cabling. A piled solution was used for both turbine foundations.

A switch-gear and metering building of traditional design was constructed on site to house the electrics.
Blantyre Muir Wind Farm
Blantyre Muir Wind Farm

Blantyre Muir Wind Farm

Blantyre Muir Wind Farm
Customer: GDF Suez
Value: £1.9m

Raymond Brown was awarded the balance of plant contract to construct a six Repower MM92 turbine wind farm in South Lanarkshire. This is one of a series of projects awarded to the team by GDF Suez.

The project involved the design and construction of civil engineering works including modifications to the site entrance, new tracks, site compound, crane hardstandings, turbine foundations, and the construction and fit-out of the wind farm substation.

Electrical works were undertaken with our partner, Powersystems UK Ltd, and included HV and LV cabling works, communications cabling, and all wind farm electrical installations within the substation. The project was approved in two stages (three turbines on phase A and three turbines on phase B) but was built as one project. Partly on a previous open cast mine site, turbines four and five were built on made ground. Turbine five has a piled foundation.

Following additional onsite ground investigation by RBC/Greencat, micro-siting of turbine four resulted in a more suitable location that removed the requirement for two metres of soil replacement. The site was shared with the land user, Greens Recycling Ltd, operating a green waste recycling centre with excellent mutual cooperation.
Carlton on Trent Wind Farm
Carlton on Trent Wind Farm

Carlton on Trent Wind Farm

Carlton on Trent Wind Farm
Customer:Farmwind Ltd/CoT Projects
Value: £256k

The scope of the project was to design, facilitate and supervise the installation of a single EWT wind turbine with grid connection within a three month period. This entailed construction of track and crane hard standing, construction of the turbine foundation, installation of a Glass Reinforced Plastic (GRP) substation and all electrical items including design and installation.

The civil engineering works were undertaken by our in-house renewables team. BSW Consultants were appointed for the civil engineering design with Powersystems UK undertaking the electrical design and installations.

It was important for our customer that the turbine was generating before 1 April 2012 because the tariffs would reduce for him if the project was completed after this date. To achieve this, every party involved had to liaise regularly to ensure that all activities were coordinated. We maintained regular contact with the turbine installation team, EWT, to ensure that they could commence turbine erection at the earliest opportunity.

The substation was a prefabricated GRP unit installed on a concrete slab cast in situ. Using a GRP unit saved eight weeks on the programme as opposed to full in situ construction. Despite disruption from severe snowfall in February, the project was completed on time.

Some key facts and figures:

- The foundation consists of 150m³ of concrete and 14T of steel reinforcement.
- The grid connection is a 750m long route. Twinwall ducts were installed in the ground from the substation to the point of connection. The cable was then drawn through by rope.
- The stone track is 100m long and 4m wide. The crane hard standing is 20m x 35m in plan. Both are made up of 6F5 grade stone before being capped off with a layer of Type 1 grade sub base to give a smooth finish.
- Local contractors were appointed for the entrance works and fencing. This included tarmac surfacing, laying of kerbs and installing a culvert to maintain an existing watercourse.
Drone Hill Wind Farm
Double Arches Wind Turbine

Drone Hill Wind Farm

Drone Hill Wind Farm
Customer: AES Wind Generation
Value: £4.3m

Raymond Brown was awarded the balance of plant contract to construct a 22 turbine wind farm in the Scottish Borders near Dunbar. The 1.3 MW N60 turbines were supplied by Nordex comprising a 46m hub height and 30m blades. The site was bisected by the A1107 and we were also contracted by Scottish Borders Council for undertaking all off-site road works.

The contract comprised the construction of 19 drained foundations of 13.3m diameter, using 19t of steel reinforcement and 186mᶟ of concrete and three submerged foundations of 15.75m diameter using 26t of steel and 280mᶟ of concrete. The contract also included the construction of 6km of 4.5m wide tracks, 6km of HV cables, the design and construction of a 33KV substation and the erection of a temporary met mast and decommissioning of a permanent met mast.

Due to an initial delay in contract award, acceleration of foundation construction and site works was required and achieved enabling us to meet the programme delivery dates for turbine components. This also ensured we adhered to the environmental restrictions placed on the project site during hen harrier breeding season (March to mid-August.)

The site provided significant challenges due to groundwater which, if uncontrolled, would flood the excavation and weaken the formations. To prevent this, stringent controls were put in place. We encountered difficult ground conditions with large quantities of peat excavated prior to the construction of foundations and crane pads. A floating track design was adopted on site as required.

To accommodate turbine delivery, a cutting for the site track along a 300m stretch of hill to achieve a 10% gradient was engineered to maximize site won rock and then reused to create tracks and hardstandings.
March Wind Farm
March Wind Farm

March Wind Farm

March Wind Farm
Customer: Anglian Water Services/ASC
Value: £363k

Raymond Brown was awarded the balance of plant contract to construct this single Enercon E70 turbine development for Anglian Water as part of a wind farm framework on their treatment works.

The project involved the design and construction of civil engineering works, including modifications to the site entrance, new tracks, site compound, crane hardstanding, and designing a piled solution that combined with a foundation design supplied by Enercon. Aarsleff Piling installed the driven piles.

A switchgear and metering building of traditional design was constructed on site to house the electrics. Electrical works were undertaken with our partner, Powersystems UK Ltd, and included HV and LV systems, communications cabling, and contestable elements for the grid connection. Over 3km of trenching was installed to enable grid connection.

The project was carried out within the works area of the operational plant with existing equipment and services above and below ground.

The project was carried out under Anglian Water's operational health and safety management system, in conjunction with our own. Anglian Water's site regulations and protocols were added to our site rule requirements to ensure compliance.
Sober Hill Wind Farm
Sober Hill Wind Farm

Sober Hill Wind Farm

Sober Hill Wind Farm
Customer:International Power
Value: £2.3m

Raymond Brown was awarded the balance of plant contract to construct this six turbine wind farm in East Riding, Yorkshire. This is one of a series of projects carried out for International Power. The scope of the project included the design and construction of:

- site entrance
- 4km of access tracks
- crane pads
- reinforced concrete foundations for six REpower MM82 2.05MW WTG
- substation building works
- wind farm electrical works including the wind farm switch gear and all on site cabling

Electrical works were undertaken with our partner, Powersystems UK Ltd and included HV and LV communications cabling. A switch-gear and metering building of traditional design has been constructed to house the electrics.

The turbines are founded in Burnham Chalk. This is a white high density rock, mainly classified as Type B3 / B4 chalk.

Sober Hill was subject to an archaeological watching brief. This mainly involved archaeologists watching the topsoil strip. It also included hand digging in areas they felt that were showing signs of archaeology. At one point there were 10 archaeologists on one crane pad.
St John's Wind Farm
St John's Wind Farm

St John's Wind Farm

St John's Wind Farm
Customer:Renewable Energy Ventures
Value: £1.8m

Raymond Brown was awarded the balance of plant contract to construct a nine turbine wind farm in Aberdeenshire near Stonehaven. On this contract we faced a particularly challenging programme. We needed to complete the construction of all nine turbine foundations, 5km of new site track, crane hardstandings and a new 33kv substation before the Christmas period. The turbines were then delivered in the New Year and generating electricity before a change in the feed in tariff took effect at the end of March.

Gamesa G58 850 KW turbines with a 48m hub height and 29m long blades were specified. RBC offered the customer two alternate base design options. The chosen foundation comprised of 21.5t of steel reinforcement and 180 cubic meters of concrete. Each foundation took approximately three weeks to build. We worked on several foundations concurrently to maximise the productivity of our workforce and reduce the overall construction programme.

The site topography contained some significant gradients which needed to be re-engineered to accommodate the delivery of the turbine components. In total we moved nearly 17,000m³ of material to achieve a running surface that this turbine suppliers specification. RBC worked closely with the three landowners at St. Johns Hill to minimise the effect of our construction activities on the day to day operations of their working farms. We presented proposals and altered our design where possible to reduce the effect of the permanent works.

We constructed a 33 KV substation, which provides a point of connection for the wind turbines to the national grid. RBC was responsible for the design of the building and electrical infrastructure, which required the approval of SSE and Gamesa before construction could commence. Due to the wet ground conditions in the area where the substation was constructed, we installed deep drainage below the level of the substructure to ensure water ingress into the deep trenches within the building didn’t become a problem.

Despite extreme weather conditions in December, January and February we were able to ensure delivery of this turbine compound on time.

Projects – Map View

To view our projects on a map of the UK, click on this link.

Our Customers

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KEY CONTACT

ENERGY (NON-WIND)

Kelly Meredith-Jones
E: kelly.meredith-jones@rbconstruction.co.uk
M: 07855 518 652

KEY CONTACT

WIND

Cath Waller
E: cath.waller@rbconstruction.co.uk
M: 07818 432 183