ISO 11 Incinerator Life Extension Project - WP 5 Refractory Replacement

The contract is for a single supplier to provide Design and Build of Work Package 5 - Incinerator Kiln Refractory Lining Upgrade to the Primary and Secondary Combustion Chambers, as per the user requirement specification (URS) for The Pirbright Institute (Pirbright), Ash Road, Pirbright, Surrey, GU24 0NF.

The scope of this contract is to replace the Kiln Refractory Lining for the Primary and Secondary Incinerator Chambers to ensure that the ISO 11 incinerator remains available to operate, safe, reliable and will serve the building for a minimum of 10 years.

The scope of works will involve:

• Detailed design and configuration of the new refractory lining and anchors based on the existing plant, drawings and documentation.
• Supply and delivery of all refractory materials and anchors.

o This would include any materials used for forming, moulding, and support structure (e.g. wood, polystyrene) and 1 tonne waste bags with sealable tops.

• Deconstruction of existing refractory lining and Anchors (Disposal of waste by others)
• Installation of the new anchors and refractory lining as per agreed detailed design.
• Management of drying out and curing of the lining.
• Management of all subcontractors employed by the supplier to complete these works.
• On completion, an O&M is to be submitted which provides details of works from design to completion. The O&M should include all relevant items shown in the PIF and a separate section which provides details of the following

o Brief Description of the works being carried out.

o Project Risk Assessment.

o Key structural principals.

o Hazardous materials used.

o Information on the future removal of installed plant.

o H&S information about equipment provided for cleaning or maintaining installed plant.

o The nature, location and markings of significant services.

o Information and as built drawings of buildings, plant and equipment.

o Step by step activities to carry out the works.

o Lesson Learnt, challenges met and how they were overcome.

o Details on how the curing burners are set up and how the ventilation and ID fans are set up to draw away the heat.

• As part of the works, the supplier should also provide the following:

o Provision to ensure safe access and egress to confined spaces (Gas monitors, Rescue Personnel, Outside Watchman, etc)

o All provisions for the deconstruction, installation and drying / curing of the refractory, including but not limited to:

 All necessary machinery and equipment required for the works.

 Provision of lighting in the individual plant sections.

 Provision of transport vehicles required for the works which is not listed as part of the CDM site below.

 Provision of weather protection for any equipment and materials used/stored outside.

 Air compressor and fuel.

 Extraction fans and filtration to minimise dust generation within area of works.

 All PPE required for safe working during all works.

 Equipment and fuel required for drying and curing of the refractory lining. Recommend diesel burner as gas would be difficult to arrange on site.

A CDM Construction site will be set up as part of the overall project which will provide for the following:

• Site Supervision
• HERRAS fencing and appropriate signage around CDM area
• Site Office
• Welfare Office including changing areas
• Waste skips
• Scissor lift
• Fork-lift truck / telehandler
• CDM documentation / inductions / daily logs / management of RAMS

Additional information:

As part of the tender, the supplier is to provide option costs and timescales for the following:

• Completion of both chambers within a single visit based on normal working hours only.
• Completion of both chambers within a single visit based on normal and extended working hours.
• Completion of both chambers over two visits (i.e. one chamber per visit) based on normal working hours only.
• Completion of both chambers over two visits (i.e. one chamber per visit) based on normal and extended working hours.