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Chimney Dismantling - OI Manufacturing, Alloa

Chimney Dismantling - Chimney Flue 85 (OI Manufacturing UK Ltd, Alloa)

Safe deconstruction of a 75-metre reinforced concrete chimney through lift-managed sequencing

 

Project Overview

GEM Enterprise prepared detailed structural weight calculations and dismantling engineering inputs for the safe removal of a 75 m reinforced concrete chimney (Flue 85) at OI Manufacturing UK Ltd, Alloa. Our remit was to enable safe lifting procedures throughout the top-down dismantling sequence. We produced a weight schedule at 1m increments, set lifting envelopes and safety factors, and issued step-by-step recommendations for cutting, rigging, and crane operations, so the contractor could plan and execute the work with confidence.

 

Client:

Pendrich Height Services Ltd

Sector:

Industrial / Process

Location:

Alloa, Scotland, UK

Date:

June 2024

Our Role:

Structural calculations, lift study constraints, dismantling methodology advice, safety factors & hold-points

Key Facts

  • Structure: 75 m reinforced concrete chimney (tapering shell)
  • Engineering output: Weight schedule at 1 m increments for lift planning
  • Minimum lifting safety factor: FoS ≥ 2.0 (crane capacity ≥ 200% of worst-case lifted weight, incl. rigging & dynamic allowance)
  • Deliverables: Weight tables, lift envelopes, sequencing notes, exclusion-zone guidance, hold-points & QA checklist

 

 

Project Challenges

  1. No maintenance/inspection history
  • Impact: Unknown wall thickness variation, reinforcement density and local defects required conservative assumptions and onsite verification.
  1. Height, taper & variable thickness
  • Impact: Accurate weight distribution per metre was critical to crane selection, rigging configuration and cut lengths.
  1. Safety-critical lifting in a live industrial setting
  • Impact: Crane siting, ground bearing, wind-speed limits, exclusion zones and communication protocols had to be clearly defined and enforced.

 

 

 

Our Solutions

  • 1) Survey, assumptions & verification

  • Compiled available drawings/records; undertook dimensional checks and visual inspection notes.
  • Established conservative material assumptions (e.g., concrete density, reinforcement allowance, any liner/insert allowances where applicable).
  • Embedded hold-points to reconcile actual measured piece-weights (via load indicator) against calculated values and update the plan if required.

2) Weight calculations & lift envelopes

  • Produced a 1 m increment weight schedule accounting for taper and thickness variation, plus rigging and dynamic load allowances.
  • Set lift envelopes and radius charts compatible with the selected crane duty, including wind limits per manufacturer’s charts and FoS ≥ 2.0.

 

3) Dismantling strategy & sequencing

  • Recommended a top-down phased dismantling: cut ring segments to controlled lengths to maintain shell stability; avoid excessive eccentricity.
  • Defined cut geometry and temporary bracing/prop allowances where local weaknesses might occur (e.g., near openings or construction joints).
  • Provided exclusion zone principles and tag-line control notes to manage swing and rotation.

4) Site safety & QA controls

  • Aligned with BS 7121 (planning of lifting operations) and BS 5975 (temporary works).
  • Required lift plan sign-offs, daily briefings, radio protocol, and a permit-to-lift process with stop rules if conditions (e.g., wind) exceeded limits.
  • Included ground bearing checks for crane mat design inputs and clear red/amber/green criteria for proceeding.

 

 

Outcomes

  • Predictable lifting operations enabled by a validated 1 m weight schedule and FoS-based crane selection.
  • Risk reduced through conservative assumptions, measured-weight reconciliation and clearly defined hold-points.
  • Efficient programme with cut lengths tailored to crane radius/duty and site logistics, improving productivity while maintaining safety.

 

 

Services Provided

Structural calculations · Lift study & duty envelope · Dismantling methodology advice · Temporary works/method constraints · Risk assessment & QA/hold-points · Exclusion-zone guidance

 

 

Why Choose GEM Enterprise?

Expertise in Complex Structural Challenges

  • Advanced Engineering Solutions: Skilled in addressing intricate structural issues through innovative engineering practices.
  • Innovative Approaches: Utilises cutting-edge technology and methodologies.

 

Customised Solutions

  • Tailored Designs: Solutions crafted to meet the specific needs of each project and client.
  • Client Collaboration: Works closely with clients to understand their requirements and achieve desired outcomes.

 

Commitment to Quality

  • Stringent Quality Control: Maintains high standards throughout project execution, from design to commissioning.
  • Safety Focused: Prioritises safety in all aspects of design and implementation, adhering to the highest industry standards.

 

About GEM Enterprise

GEM Enterprise specialises in comprehensive structural and civil engineering services. Our experienced team is dedicated to delivering innovative, safe, and efficient solutions for complex engineering challenges. With a commitment to excellence and client satisfaction, we provide services ranging from structural assessments to the design and implementation of bespoke engineering solutions.

Get in touch with our experts today.

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