Innovative GRP Tank Covers at Berry Hill STW

In the water treatment industry, "standard" solutions often don’t cut it when dealing with complex, multi-level infrastructure. A standout project at Berry Hill STW demonstrates how Corporate Engineering utilises clever design to integrate high-performance GRP tank covers with existing mechanical equipment.

Working with Stortec Engineering Ltd for Wessex Water, we were tasked with providing a high-performance cover for a specialized 18m diameter Demon Reactor Tank.

Completed cover prior to access bridge installation

The Challenge: Precision Engineering Under Pressure

The project required more than just a simple tank seal. The new cover had to be meticulously designed to sit beneath a Galvanized Mild Steel (GMS) bridge while still providing full functionality.

The primary requirements included:

• Low-Profile Integration: The cover needed to fit seamlessly under the overhead access bridge.

• Operational Access: Personnel required safe access to sampling points, mixers, and the central inlet chamber.

• Live Equipment Clearance: The design had to accommodate cover-mounted equipment without compromising the tank's seal or structural integrity.

  
  

The Solution: GRP Tank Covers using the "Beam and Infill" Approach

To meet these spatial constraints, Corporate Engineering utilized a Beam and Infill GRP design. This modular approach allowed for a low-profile installation that didn't sacrifice strength.

New mixer hatch designed to project through the GMS access platform.

Key Technical Features:

• Load Bearing Deck: The cover deck was engineered to support an imposed load of 3kN/m², providing a stable platform for operations personnel to access process equipment.

• Specialist Hatching: We integrated a variety of inspection and sampling hatches, including a custom large twin-door mixer hatch. This was specifically designed to project through the GMS access platform, allowing for easy maintenance from the overhead walkway.

• Central Inlet Access: The design ensures the central inlet chamber remains fully accessible from the cover deck.

• Durability: As with all our GRP installations, the material offers superior resistance to the humid, corrosive environment of a reactor tank, far outlasting traditional timber or un-treated metal alternatives.

Central inlet chamber is accessible from the cover deck above.

Project Summary

Feature	Detail
Client	Stortec Engineering Ltd / Wessex Water
Location	Berry Hill STW
Tank Type	18m Diameter Demon Reactor Tank
Load Rating	3kN/m²
Completion	2020

We’ve Got You Covered

From large-diameter reactor tanks to intricate inlet chambers, Corporate Engineering provides the design expertise and manufacturing quality (ISO 9001:2015) to solve the water industry's toughest covering challenges.

Does your next project involve complex site constraints?

Let us design a GRP solution that fits your specific footprint and operational needs.

Get in touch with our technical team:

• Email: sales@grpcovers.com

• Website: www.grpcovers.com