Delivering complex sludge treatment infrastructure through digitally engineered, offsite manufacturing.
Merit was appointed by Tamesis to design, manufacture and install the mechanical process systems for two Advanced Anaerobic Digestion (AAD) facilities at Beckton and Crossness in London.
The schemes form part of a major infrastructure investment to transform sewage sludge into renewable energy through advanced anaerobic digestion. Using a two-stream thermal hydrolysis process, the facilities increase biogas production by breaking down sludge more efficiently under elevated temperature and pressure.
Working as the mechanical design and build specialist, Merit applied a digitally led, offsite delivery strategy that combined 3D modelling, modular steelwork, process pipework and prefabricated assemblies to improve installation efficiency, minimise site disruption and deliver consistent quality across both sites.
- Client
- Tamesis (JV between Laing O’Rourke, Imtech Water, Waste & Energy)
- Location
- Invergordon, Scotland
- Sector
- Energy
- Project
- Offsite prefabrication and installation of pipe spools
Key Features
- Digitally engineered process pipework and modular steelwork using comprehensive 3D modelling and site surveying.
- Extensive offsite manufacture and prefabrication of mechanical modules, complete with integrated electrical containment.
- Standardised modular design philosophy to improve repeatability, simplify installation and reduce onsite interfaces.
- Full material traceability and controlled factory quality assurance throughout fabrication, assembly and delivery.
Key Outcomes
- Reduced onsite welding from approximately 7,000 welds to just six, significantly improving safety, programme certainty and installation efficiency.
- Accelerated site installation through modular construction, reducing labour requirements, trade clashes and site congestion.
- Lowered structural weight and associated costs through the adoption of lightweight metric bore stainless steel tube and innovative support systems.
- Delivered high-quality, fully traceable prefabricated assemblies manufactured in a controlled factory environment, improving quality assurance and simplifying commissioning.
