Connell Brothers have recently completed the de – planting and demolition of the former Degussa Manox Facility in East Manchester. The majority of the contents of the site was carefully dismantled, placed in shipping containers and relocated to China were it was rebuilt and reused.

The site closed down in April 2005 and many local residents were glad to see the end of what was considered a major eye sore in the area. The clearance of the plant has also enabled the potential regeneration of the approximate 40 acre site.

The facility has historically been used for the manufacture of chemicals since 1864. Since the 1960’s the site had been used for the manufacture of various types Manox blue an additive which was put into inks.

Connell Brothers were faced with a variety of unique challenges during the course of these works. The main scope of the contract was the de – planting of the vast majority of the manufacturing plant items which were to be retained and shipped out to China where they were rebuilt and reused.

De – planting took place in the former manufacturing facility which included The Verico Spray Drier Plant, The Easieperse Plant, The Blue Mill, The VAT Farm and The YPS Plant.

Prior to the de – planting operations it was necessary to undertake a large two phase decontamination operation. First all dry blue powder products were removed using vacuum tankers. The second phase of decontamination was the removal of the residual blue powder product. The only way to remove this was to use a mild caustic solution under a high pressure spray. The decontamination was conducted on all plant, internal building surfaces, internal and external areas of hardstanding, gantry walkways, and the like.

Following the decontamination works all wash water runoff was collected and treated in an on – site effluent treatment plant prior to discharge, under a temporary discharge consent which had to be obtained and agreed with United Utilities.

Connell Brothers were solely responsible for the running and operation of the on site effluent treatment plant, and two site staff were specifically trained in its operation and the monitoring of Ph Levels.

Once the first stage of decontamination complete all plant, tanks, equipment and spares as listed in the clients asset register were carefully removed. Prior to the de – planting operations Connell Brothers designed, manufactured and installed a number of unique lifting cradles to assist with the removal of the plant and to assist with the rebuilding works oversees. The cradles would allow the plant items to be slotted into their new structures without the need for further fabrication, thus saving time and money.

Once removed the plant was transported on low loaders across the site to a bunded area for a final re – clean prior to re – loading onto lowloaders and containers to commence the journey to China.

Somewhere in the region of 60 loads were removed from site.

A specific identification system was devised where all items of plant where allocated with code numbers which corresponded to construction drawings to ensure that the reassemble operations in China would be conducted with no problems. A further challenge Connell Brothers faced was working adjacent to the Rochdale Canal.

All works were conducted in strict compliance with the British Waterways Code of Practice. Furthermore all demolition rubble was confined to the areas comprising the footprint of existing buildings and bunded areas so that any blue leachate runoff from the hardcore was contained in sumps.

A Water pump then transported the substance to the on site effluent treatment plant prior to discharge. This control measure was put in place to minimise the risk of leachate runoff into the storm water sewers.

Prior to demolition background air monitoring was undertaken daily for one week. Samples were taken for asbestos, total inhalable dust and respirable dust content. Action levels were agreed prior to commencement based upon the background levels and local sensitivity.

The main demolition works were carried out under a strict regime of daily air monitoring where Connell Brothers had to install frisbee directional dust deposit gauges at each monitoring station in order to collate the results. The results were carefully analysed and procedures were put in place for action where necessary.

Connell Brothers undertook a strict regime of Health Safety and Environmental auditing in conjunction with Degussa throughout the contract which enabled the works to be completed on time without accident or incident.

Connell Brothers health and safety record has once again been recognised by The British Safety Council who have awarded the company with their National Safety Award the eight successive year.