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FLI Precast Solutions

FLI Precast Solutions (formerly FLI Carlow) provide design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems. Our markets include Water, Wastewater, Energy and Storm Attenuation in the UK & Ireland and bespoke projects globally.

Services include:

Design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems.
Design to national and international water industry standards and our semi-precast modular designs make us the industry leader in off-site concrete engineering and manufacture.
By early involvement and integrating with our clients’ design teams we can accelerate and improve design optimisation and reduce cost. The value is in the solution, and off-site manufacturing and fabrication leads to higher efficiencies and lower risks and costs.
Framework agreements enable us to add more value through collaboration, innovation, economies of scale, supply chain partnering and cost management.
Our products and designs are engineered to provide solutions to many challenges facing our clients: water retention, water storage, water conveyancing, water management, water treatment, fire-resistance criteria, chemical resistance parameters, infrastructural products, retaining walls, coastal erosion, decorative walls, to name a few.
We are a solutions provider using innovative off-site concrete engineering and our industry leading semi-precast modular designs.
The company is part of the FLI Group which is a diversified group of companies providing environmental solutions, services and technologies to private and public sector customers in the UK, France, Ireland and throughout the world.

Products include:

Attenuation	Channel and lids
Reservoirs	Multi-purpose chambers
PST and AST tanks	Comms chambers
Holding tanks	Bespoke culverts
Barriers	Dry flow channeling
Demountable fence supports (International Airport Approved)	Foundation bases
Chambers	Blast fence supports
Culverts	Lined tanks
Ballast blocks

Ufton Nervet WTW (2023)

Water quality and structural integrity risks managed whilst maintaining ‘island zone’ customer supplies

Carlisle WwTW (2022)

A £36.6m project to enhance discharges into the River Eden and protect shellfish in the Solway Firth

Rothbury STW (2022)

Upgrade to replace primary tanks and new tertiary HSAF plant

Barkers Haugh STW (2021)

An £8m upgrade to respond to catchment growth and a ratcheted total iron consent

Ludham Licence Reinvestment (2021)

Securing a new water source, combining schemes and using off-site build to meet the supply demand challenges in Norfolk

Bewdley Bank Service Reservoir (2020)

A procurement-based approach to the design and construction of a new semi-precast concrete Service Reservoir for Hereford and the surrounding area

Testwood Water Supply Works (2020)

Capital maintenance scheme and large scale refurbishment of the rapid gravity filters in Southampton

Bryn Cowlyd WTW (2019)

Welsh Water’s flagship AMP6 scheme improves water quality for almost 100,000 customers

Pegswood STW (2019)

Replacement primary tank and new tertiary NSAF/DBF plant

Testwood Water Supply Works (2019)

Phase 1: Capital improvement scheme to increase output from 70Mld to 91Mld and improve the resilience of supplies to Hampshire and the Isle of Wight

FLI Precast Solutions – Gowerton WwTW

Blending Chamber and PFET for Dŵr Cymru Welsh Water

By: FLI Precast Solutions

Published: September 08, 2019

Precast concrete structures under construction - Courtesy of FLI Precast Solutions

Project Information

Location: Swansea
End client: Dŵr Cymru Welsh Water
Main contractor: Morgan Sindall
Start date: July 2018
Scope of works: Design, manufacture, delivery and installation of the PFET and Blending Chamber structures for Gowerton WwTW

Background

The reasoning behind the works at Gowerton was a requirement to meet permit conditions in South Wales by 2020. It is a cost-effective approach to challenging flow management at Water Treatment works which enables DCWW to meet their spill permit regulations as laid down by the Welsh Government and Natural Resources Wales.

The client was working to an extremely tight programme to achieve consent dates, which meant that the FLI Precast Solutions precast construction methods delivered key advantages over the traditional build process.

On completion of the design the precast panels were produced off site at the same time as the 500,000m³ excavation was undertaken to receive the panels. The area was suitably prepared for the delivery of the panels which was coordinated with the site team and the client’s operators to facilitate the existing treatment process.

Key drivers for the scheme included the requirement for complex M&E integration which also lends itself to the FLI Precast Solutions design and production philosophy for off-site manufacture.

Precast concrete structures under construction - Courtesy of FLI Carlow

Precast concrete structures under construction - Courtesy of FLI Precast Solutions

The Gowerton scheme is the first project in the UK to utilise American company WesTech’s Flexfilter technology. WesTech are partnered with FLI Water to deliver systems to the UK water market.

Solution

Controlled production of elements to a very high standard.
Integration of complex M&E systems.
Reduced H&S risk on site.
Programme savings in the works through a shorter construction programme.
Reduced workforce on site resulting in reduced main contractor preliminaries.
Reduced construction traffic for the local area, meaning less disruption for residents.
Lower carbon footprint as a result of the FLI Precast Solutions construction methodology, which is typically half that of traditional in-situ build.
Flexibility for programme phasing on site, if necessary
All units manufactured off-site and called in as dictated by the programme.
FLI Precast Solutions provide a secondary sealing system which traditional methods do not offer.
Clear works development through Building Information Modelling (BIM) and cutting-edge design capability.

Precast concrete structures under construction - Courtesy of FLI Carlow

Precast concrete structures under construction - Courtesy of FLI Precast Solutions

A word from our client

“The scheme involved installing various complex precast structures to house a new flexseal treatment system that will deal with foul water storm flows before discharging to the consented outfall, the first of its kind in Europe. The PFET structure alone was 27m x 26m x 8m deep (at the deepest part), consisting of 3 different levels and various interconnecting chambers.

Due to the high priority of the scheme and the tight deadlines to meet NRW consents, a precast option was progressed. This enabled the design of the structure to be passed to FLI Precast Solutions which released our design team to concentrate on other areas of the scheme, showing significant programme savings on the design.

Due to the competency and efficiency of the FLI Precast Solutions team the precast installation was completed on time with zero accidents/incidents and to the end client’s satisfaction.”

Kevin James, Project Manager - Wastewater Infrastructure, Welsh Water Capital Delivery Alliance

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