Project Case Study: Thermeco Malvern Waste-to-Energy Plant Refurbishment
- SAS Scaffolding
- Jun 18
- 3 min read
Updated: Jul 2
Project Overview
SAS Scaffolding was appointed by Refractory Engineering Services to provide a comprehensive scaffolding and access solution for the refurbishment of the Thermeco waste-to-energy plant at Clinitek (Malvern) LLP's healthcare waste incinerator facility in Worcestershire.
The project involved the complete refurbishment of the waste-to-energy plant, requiring a range of bespoke access and support structures to facilitate safe demolition, refurbishment, material handling, and installation works throughout the facility. Originally programmed for 12 weeks, the project was extended to 16 weeks due to additional works and remains ongoing.
Key Facts
Client: Refractory Engineering Services
Location: Clinitek (Malvern) LLP, Haylers End Healthcare Waste Incinerator, Hangmans Lane, Hanley Castle, Worcestershire, WR8 0AJ
Project Duration: January 2026 – Ongoing
Original Programme: 12 Weeks
Extended Programme: 16 Weeks+
Scaffold Height: 8m
Number of Lifts: 4
Scaffold Type: Bespoke Temporary Roof & Storage Facility, Loading Bay, Loading Gantry, and General Access Scaffolding
Project Scope
To support the extensive refurbishment works, SAS Scaffolding designed and installed a range of specialist access solutions tailored to the operational requirements of the site.
A bespoke temporary storage facility with integrated weather protection was constructed to provide secure storage of materials and equipment during the project. A four-lift general access scaffold was erected to provide safe access to key working areas, incorporating stair access, ladder access, loading bays, and loading gantries to facilitate the movement of personnel and materials.
Additional structures included:
Internal access tower connecting the external loading bay area to the internal crash deck.
Internal crash deck beneath the roof removal zone to protect personnel during demolition works.
Handrail systems installed around the top of the incinerator structure.
Access tower for steel beam installation works.
External scaffolding for roof section removal.
Scaffolded access through a newly created doorway within the loading bay area to improve access between work zones.
Challenges
The refurbishment of an operational waste-to-energy facility required careful planning and coordination to ensure safe access for multiple trades working simultaneously within a confined industrial environment.
The project demanded a combination of internal and external access solutions, material handling facilities, fall protection systems, and temporary weatherproof storage structures. As the scope of works evolved, the scaffolding design and programme were adapted to accommodate additional client requirements while maintaining safety and operational efficiency.
Project Delivery
Working closely with Refractory Engineering Services, SAS Scaffolding delivered a phased installation programme to align with the refurbishment schedule.
All scaffold structures were designed, erected, and inspected in accordance with current industry standards and site-specific requirements. Regular inspections and ongoing modifications ensured that access arrangements remained suitable as works progressed and project requirements changed.
The integrated approach allowed safe access to elevated work areas, supported roof removal operations, facilitated material handling, and provided protected workspaces throughout the refurbishment programme.
Results
The scaffolding infrastructure successfully supported the ongoing refurbishment of the waste-to-energy plant by providing:
Safe access for multiple trades across all work areas.
Secure material handling through dedicated loading bays and gantries.
Protected working environments through crash decks and temporary weatherproof structures.
Flexible access solutions adapted to changing project requirements.
Continued support throughout the extended programme duration.
Conclusion
This project demonstrates SAS Scaffolding's capability to deliver complex, bespoke access solutions within demanding industrial environments. Through careful planning, technical expertise, and a flexible approach to evolving project requirements, SAS Scaffolding continues to support the successful refurbishment of the Thermeco Malvern waste-to-energy facility while maintaining the highest standards of safety and operational performance.
Project Gallery
Comments