Steel Structure and Wash Plant Upgrades

Client:Cemex UK
Type:Design, fabrication and installation project

Project Overview

Thor Atkinson Steel Fabrications were commissioned by Cemex UK to deliver a series of major upgrades to the aggregate wash plant at their Poole Wharf site in Dorset. The project formed part of a significant modernisation programme and encompassed full design, steel fabrication, demolition, and installation works.

To enable the new installations, our specialist industrial demolition partner, N&R Contractors, was engaged to safely remove the existing sand plant and associated steelwork, which had suffered extensive corrosion.

The Challenge

The existing wash plant infrastructure had reached the end of its service life and required replacement while maintaining alignment with Cemex’s operational and performance requirements. The scope demanded a carefully phased approach to demolition and installation, alongside bespoke steel design and fabrication to integrate new plant and equipment into the existing process.

Our Solution

We delivered a comprehensive, end-to-end solution covering design, fabrication, and on-site installation. Key elements of the works included:

Upgrade of the sand plant steel structure and chutes to accommodate a new sand plant
Replacement of the primary screen with a new Hewitt Robins screen, including the design and installation of a new screen building
Design, fabrication, and installation of a new sand plant steel structure, along with installation of the sand plant supplied by Cemex
Installation of new 10/20mm steel structures and discharge chutes
Installation of a new primary screen complete with supporting steelwork and access walkways
Replacement of a conveyor head end, fabricated and painted at our Cumbria workshops prior to delivery
Replacement of walkways, support steelwork, and pipework to the existing Haith thickener, including the addition of a diffusion drum and rake frame to ensure even distribution of flocculant within the water system
Refurbishment and subsequent replacement of the crusher feed conveyor, including the design and manufacture of a new diverter chute and conveyor, fully integrated into the existing system
Design, fabrication, and installation of a new surge bin and crusher support structure to accommodate the refurbished crusher

Project Delivery

All steelwork was designed and fabricated in-house, ensuring quality control and programme certainty. Installation works were carried out by our experienced site teams, working closely with Cemex to coordinate activities and minimise disruption to site operations.

Safety and Compliance

The project was delivered under strict health and safety controls, with all works planned and executed in line with CDM Regulations. Close coordination between fabrication, demolition, and installation teams ensured safe sequencing and efficient delivery throughout.

Outcome

The upgraded wash plant significantly improved operational efficiency, reliability, and maintainability at the Poole Wharf site. The successful integration of new plant, bespoke steel structures, and refurbished equipment delivered a robust, future-proof solution aligned with Cemex UK’s long-term operational goals.

For all steel structure design, fabrication and installation projects for the aggregate industry contact Thor Atkinson directly on 07798 684 289 or get in touch via our secure on-line form.