In 2017, Mactech Energy Group was introduced to the Hinkley Point C project, one of the largest nuclear power stations in Europe, through our work on the Cooling Water (CRF) Pipes contract. As a key supplier for a tier 1 contractor, we provided the full in-scope UK workforce to support the installation of critical infrastructure for the nuclear power station’s cooling systems.

The scope of work involved the welding, lifting, and installation of seawater intake and discharge pipes, connecting the pumping stations and outfall buildings to the condenser modules in the turbine halls of the conventional island. These large-scale pipes play an essential role in ensuring the reactors operate efficiently and safely.

The installation of the CRF pipes was a highly technical and demanding task, with each of the 700 concrete-encased steel core pipes weighing 30 tons. These pipes were welded in-situ on site by stove welding and required precise handling to lift, transport, and position them in place.

Managing the logistics of this operation, while ensuring adherence to the highest standards of safety and regulatory compliance, posed a significant challenge. Additionally, the project required a diverse range of specialised roles, including lifting supervisors, coded welders, riggers, steel fixers, shuttering carpenters, and concrete workers, all of whom needed to work in perfect coordination.

Mactech provided a Total Workforce Solution for the project, supplying a peak workforce of nearly 100 in-scope workers, covering every aspect of the CRF pipe installation process. This workforce included specialists in welding, lifting, and construction, ensuring that every phase of the operation was expertly managed.

Key components of our solution included:

• Lifting and welding expertise for handling the installation of the massive 30-ton pipes.
• Providing skilled tradespeople, including steel fixers and concrete workers, to ensure the structural integrity of the installations.
• Payroll management for the entire workforce on behalf of the client, ensuring smooth and efficient administrative operations.
• Full industrial relations support, including participation in monthly Local Joint Committee meetings alongside the principal contractor and unions, to maintain strong worker relations and project harmony.

This was also the first contract on the Hinkley Point C project to encompass both civil (CESA) and mechanical (ECSA) project agreements, further showcasing the flexibility and range of Mactech’s staffing capabilities.

Mactech’s contribution to the CRF Pipes contract was marked by a world-class health and safety record, with more than 1.2 million man-hours worked without a Lost Time Accident (LTA) or RIDDOR. This achievement was consistently recognised by the principal contractor at their annual Performance Awards, highlighting the quality of leadership from the tier 1 contractor and the commitment to safety from our team and the workforce.

Over the course of three and a half years, Mactech played a pivotal role in the successful installation of the CRF pipes, ensuring that this critical component of Hinkley Point C’s cooling infrastructure was completed on time and to the highest standards.