Innovate UK R&D project

From November 2014 to November 2018 Caunton Engineering Ltd, based in Nottingham UK, in partnership with the Steel Construction institute (SCI) worked on an Innovate UK funded project that demonstrated, over the course of a four year period, that Modular Walling Systems Ltd patented STEEL BRICKS® product could revolutionise Nuclear construction by demonstrating large reductions in construction programme and a lowering of construction costs. The implementation of STEEL BRICKS® modular systems makes the adoption of a conventional reinforced concrete construction solution redundant.

The various work packages were as follows

WP1 - Basis of Structural design method

WP2 - Preparation of a preliminary design of the Diesel Ultine Secours building (DUS). EDF Backup Diesel Generator Building.

WP3 - Manufacturing trial to optimise technology - Completed

WP4 - Perform Workshop erection trials to refine component manufacturing and erection, and use in concreting trials

WP5 - Design Suitable Concrete mixes suitable for use in SC (steel concrete) construction

WP6 - Perform concreting trials on panels and sub-assemblies

WP7 - Concreting of STEEL BRICKS® modular systems used for walls and floors and then dismantling of concrete slabs - this is on-going

WP8 - Refine the approach to design detailing concreting and dismantling

WP9 - Detail design of diesel generator building

WP10 - Prepare BIM/3D model of the building and prepare detailed fabrication drawings

WP12 - Prepare construction site and build foundations

WP14 - Presentation samples in readiness for site visits

A good overview of the project can be found here

Projects 1
Projects 2
Projects 3
Steel Bricks 4

Finished build

Projects 5

The project culminated in a Dissemination Day with detailed presentations to an eminent audience including representatives from Arup, CH2M Hill (now Jacobs), CRA Risk (Now Assystem), EAT Ltd, Innovate UK, Mott Macdonald, MMI Thornton Tomasetti, Office for Nuclear Regulation (ONR), Rolls Royce, Jacobs (Previously Amec Foster Wheeler) and Tarmac. The project continues to attract some repeat visitors as well interest and visits from AECOM and G.E. Hitachi.

The Small Modular Reactor market is no doubt beginning to move forward with numerous articles continuing to appear in the Global press.

Dissemination Day 1

Not only was the eventual test build on show but all the samples that had been created during the re-iterative design, fabricate and test phases.

Dissemination Day 2

A STEEL BRICKS® sculpture park contained all the exhibits and highlighted the advantages and disadvantages of alternative solutions as well as how differing concrete mixes flowed through the various configurations.

Dissemination Day 3

One of the floor system modules was part filled with concrete and accessed via a staircase that itself did not require foundations as the STEEL BRICKS® solution enabled it to be fixed directly to a wall and floor module.