Case Study 01 : Fire Cladding Stock Tank

NSG were awarded the contract for the refurbishment of the fire protective coating to a Methyl Chlorine stock Tank by INEOS Chlor Vinyls.

The project required the removal of existing cementious fire cladding, blasting cleaning to SA2½ ISO 8501-1:1988 and spray and hand application of a thick film epoxy intumescent coating to achieve a fire case of 2 hour part pool and part jet fire.

A scaffold enclosure was erected to provide a habitat including the installation of heating and dehumidification for the application of the specialist coatings.

The work was completed on time and in budget during one of the worst winters on record.

Case Study 02 : Construction of New Sulphuric Acid Converter

The project was for the replacement of a Sulphuric Acid Converter Vessel for INEOS Enterprises on Runcorn Rocksavage Works.

The COMAH registered (Control of Major Accident Hazards Regulations 1999) Sulphuric Acid Plant is located on a site adjacent to chlorine and chlorine derivative processing systems which added an additional risk to the project as chlorine has the potential to cause a failure in stainless steels.

To reduce the risk of chloride contamination from the atmosphere affecting the Stainless Steel, the vessel was constructed within an encapsulated scaffold.

The 22.6m high, 8.4m diameter stainless steel vessel was designed by Kvaerner Chemetics and constructed by Cordell under the management of Aker.

NSG successfully completed the very complex access and insulation challenge at the Ineos site in Runcorn, Cheshire in December 2010. The convertor had to be constructed to a very tight deadline and presented a number of construction challenges. The new convertor had to be installed almost adjacent to the existing convertor in a very tight space and with a number of chemical hazards present. The new vessel was to be situated on a new reinforced concrete foundation and fabricated and built whilst the plant remained operational to reduce production losses with connecting pipe work being completed during a brief outage.

The vessel was fabricated in sections off site, for delivery and assembly during a twenty seven week programme on site.

NSG were commissioned by AKER Solutions Ltd of Birchwood, Warrington, Cheshire to design a freestanding scaffold structure 24m in height and 16.4m in diameter, cylindrical in shape with the added challenge of a removable roof, which was completely water tight and could be built to a challenging construction programme deadline. The structure also had to be capable of withstanding storm force winds, lightning strike and snow.

Case Study 03 : Workington Train Station

Following the floods in Cumbria in 2009 which forced the closure of Workington station and the building of a temporary station, Northern Rail and Network Rail invested in the refurbishment of Workington Rail Station.

NSG were contracted to undertake the painting of the platform canopies and columns, including the removal of existing paint by grit blasting.

Case Study 04 : Painting of Calder Heli-Deck

This was the first opportunity that NSG UK ltd had been given to undertake work offshore for Centrica energy, and it was a challenge that was readily accepted by the team concerned with the delivery of the contract.

The specification involved the complete removal of the existing coating using a UHP water vacuum deck blast and the application of Leigh's Paints Epidek M339 Hi Profile High Build Deck Coating and the marking out and reinstatement of the identification markings. All works had to be completed to strict specifications as laid down by the Civil Aviation Authority.

Due to the isolated nature of the platform great attention to detail was required during the planning phase concerning the logistical supply of all the specialised plant, labour and materials, to ensure that everything arrived onto the platform when required in order to complete the contract within the timescales and budget allowed.

All work was completed to a high standard of quality on time and within budget, with no health and safety issues. 

Case Study No.5 – Painting of Sphere using Rope Access

NSG were contracted to apply a weather-proof protective coating to the exposed firecrete on the upper hemisphere of a Sphere. The spheres sit in an exposed position on the edge of the Mersey estuary and the firecrete was starting to suffer damage through exposure to the prevailing elements.　 Two coats of Leighs M905 and C137 were applied over five days by the rope access team, consisting of two rope access technicians and a supervisor.

Areas that require access at height such as the Spheres are examples of where NSG use Rope Access techniques to provide a safe and innovative solution which offers value for money to our client.　 　We regularly deploy IRATA trained rope access operatives to carry out Painting, UTC Inspection and Insulation Works.

Case Study 06 : Repainting of steel work to underside of road bridge flyover

NSG were contracted by Balvac to prepare and repaint steelwork to the underside of a road bridge flyover for Wirral Borough Council.   The works involved the preparation of all steelworks to the national highways schemes specifications, this included the removal of existing coatings using a combined method of wet and dry blasting techniques followed by a three coat system utilising the Leigh's paints Transgard paint coatings

The major problem to overcome during the course of the works, was the existing paint coatings that contained a high level of lead concentration. This meant that the highest level of medical monitoring of our operatives had to be maintained and additional levels of protection put in place so no contamination of the local environment occurred. It also put additional constraints on the waste generated to ensure that it was correctly handled and disposed of by a licenced hazardous waste handler.

All work was completed within the ten week schedule to a high standard of quality and within budget, with no health and safety issues