Allelys, a heavy haulage and project cargo handling specialist, has completed the transport and installation of crucial equipment for the Hirwaun Power Station upgrade project.

The project involved transporting three massive components – a 309.5-tonne turbine, a 326.1-tonne generator, and a 221.8-tonne transformer – from Newport Docks to the power station.

Planning for this complex undertaking began in June 2022 with extensive route surveys and assessments. Over 80 bridge structures were evaluated, along with necessary tree trimming and street furniture adjustments, to identify the most suitable transport route.

An unexpected challenge arose due to construction work on the A465, which reduced the weight capacity of the River Taff Bridge. Allelys responded swiftly by engineering a 17.5-meter-long overbridging solution to distribute the weight of the cargo and ensure safe passage across the bridge.

The initial leg of the journey utilized a 28-axle girder frame to transport all three components together. Upon reaching a designated point, each component was meticulously transferred onto a separate 17-axle flat-top trailer using a 400-tonne hydraulic lifting system. This configuration allowed for better maneuverability on the route’s second section, characterized by limited space and a steep incline. The entire journey was conducted under police escort with comprehensive traffic management measures in place.

Reaching the power station site, the three units underwent another transfer operation, this time mounted onto SPMT (Self-Propelled Modular Transporters) to navigate the limited space within the facility. A hydraulic gantry system was then employed for the installation of the turbine and generator, while a jacking operation positioned the transformer.

“The route from Newport Docks to Hirwaun Power Station was particularly challenging and required the input from the engineering team alongside our route survey and route planning specialists,” explained Shahid Islam, Project Manager at Allelys. “Allelys pride ourselves on inheriting our clients’ problems and providing a cost-effective, workable solution. Throughout this complex undertaking, given the limited space available and the steep gradient, we designed the perfect strategy. A solution that ensured both the weight and stability were expertly managed.”

Allelys’ successful completion of this project underscores their expertise in handling large-scale and complex heavy lifting operations, ensuring the smooth execution of critical infrastructure upgrades.