Salthome Power Station

Modularisation of Structures


Statera / Technica



Project Overview

Statera Energy had commissioned the construction of a new 50MW gas-fired power station at their site in Saltholme, Stockton-on-Tees. GGP Consult were contracted to develop steel structures to be installed as modular units to speed up installation. Our remit included calculations and fabrication drawings to be produced to a tight programme during a worldwide pandemic. 


The Challenge

The original design of the structure and ancillary buildings for the new power plant in Saltholme had been indicatively produced by engineering consultants Nicholas O’Dwyer. However, client Statera Energy required certain structural elements to be installed as pre-assembled modules, and in some cases with pipeworks already fitted. We need to work with an existing design, alongside mechanical and piping engineers to come up with a solution in a timely manner. Add into this the restriction of a worldwide pandemic prohibiting work patterns GGP Consult rose to the challenge. 


The Solution

In early 2020, GGP Consult travelled to Germany to meet engine suppliers and mechanical designer MAN Energy Solutions. Working with MAN, client Statera, piping designer and fabricator Technica, GGP Consult began to develop the requirements of installing several Pre-Assembled Units (PAUs) to allow various segments of piping to be fabricated off-site and installed onto the PAUs, which in turn were installed onsite at an accelerated rate.

Our work involved taking the generated IFC models from MAN and first carrying out structural analysis and design, then developing Tekla 3D models to meet geometric and functional requirements in several areas of the site. 

The delivery of the works was coordinated with the installation requirements, and regular meetings with Statera, MAN, and Technica allowed all parties to work closely to produce a first-class output.

Add into this the restriction of the Covid 19 UK lockdown, GGP rose to the challenge of continuing our production output and meeting all deadlines, while working remotely from both GGP colleagues, and all other parties involved. 


The Result

Through close coordination between all parties GGP produces first class professional packages for all areas;

  • The internal Mezzanine floors with skid PAUs
  • Walkways around all 4no engines
  • The external piperack split into 4no units immediately behind the main engine house
  • The radiator structure with a combination of pie-small steelwork and PAUs

Such was the quality of GGPs fabrication packages that we did not receive any requests to alter our work, or any instances of adjusting drawings through either incorrect detailing or omissions. The steel fabrication company involved used the packs produced to install all items with no further input from GGP, speaking volumes on the accuracy of our work.

This was the first project working with Statera and we have gone on to both tender and successfully win significant amount of further work with them, including numerous battery store locations across the UK.