Ferrybridge C Power Station
Ferrybridge C Power Station
Client: Keltbray (Demolition Contractor) / SSE
Location: West Yorkshire
Ferrybridge C Power Station operated for 50 years before closure in 2016, requiring staged demolition of six hyperbolic cooling towers, two 198-metre chimney stacks, and large suspended boiler and bunker house units between 2019 and 2022. The site's proximity to the River Aire and surrounding residential areas demanded precision demolition methodologies with strict environmental controls.
6
cooling towers to be demolished under a controlled environment
198m
tall reinforced concrete chimney stacks (x2) demolished
250m
exclusion zone for consistent safety standards and to protect residential properties
Our role
Our roleWentworth supported Keltbray's design and construction teams from early stages through project completion across multiple demolition phases. Our work included 3D finite element modelling of chimneys, cooling towers and suspended boiler/bunker units, centre-of-gravity tracking at each pre-weakened stage, and stability assessments under vertical, lateral, wind and notional loads.
We designed temporary works, including jacking systems, local bracing and propping, to maintain stability during member cutting. We developed bespoke demolition methodologies for sensitive structures, conducted blast and structural assessments for explosive placement, and provided rapid response engineering support as site conditions evolved throughout the three-year demolition programme.
We designed temporary works, including jacking systems, local bracing and propping, to maintain stability during member cutting. We developed bespoke demolition methodologies for sensitive structures, conducted blast and structural assessments for explosive placement, and provided rapid response engineering support as site conditions evolved throughout the three-year demolition programme.
Capabilities
Capabilities- Demolition
- Strategic Decommissioning
- Structural Engineering
- Geotechnics
- Specialist Lifting & Jacking
- Construction Engineering
- Temporary Works
Designing sequential jack-down demolition
Designing sequential jack-down demolitionThe barge unloader structure sat immediately adjacent to the River Aire, posing a significant contaminant risk if conventional top-down methodologies were used, as debris could enter the river.
Wentworth developed a sequential ‘jack-down’ approach that inverted the typical demolition sequence. This involved supporting sections of the building using jacks, cutting them, lowering them in controlled stages, and repeating the process until most of the structure was demolished to grade level. We conducted centre-of-gravity calculations to justify the position and capacity of the jacks, applied wind and notional loading in various directions to verify lateral stability during each stage, and performed finite element analysis to confirm structural capacity at each cut while tracking how the centre of gravity shifted throughout the sequence.
This bottom-up methodology eliminated the risk of river contamination and gave Keltbray the certainty to proceed with demolition at this environmentally sensitive location without conventional debris protection systems.
Wentworth developed a sequential ‘jack-down’ approach that inverted the typical demolition sequence. This involved supporting sections of the building using jacks, cutting them, lowering them in controlled stages, and repeating the process until most of the structure was demolished to grade level. We conducted centre-of-gravity calculations to justify the position and capacity of the jacks, applied wind and notional loading in various directions to verify lateral stability during each stage, and performed finite element analysis to confirm structural capacity at each cut while tracking how the centre of gravity shifted throughout the sequence.
This bottom-up methodology eliminated the risk of river contamination and gave Keltbray the certainty to proceed with demolition at this environmentally sensitive location without conventional debris protection systems.
Controlling explosive demolition
Controlling explosive demolitionThe site required controlled explosive demolition of two 198metre chimney stacks and large suspended boiler and bunker house units. The structures had to collapse into pre-defined drop zones while maintaining stability during extensive pre-weakening operations, all within 250 metres of residential properties. Linear shaped explosive charges needed precise placement to create predictable pivot and collapse mechanisms without endangering surrounding assets.
We developed 3D finite element models of the chimneys and large suspended boiler/bunker units, analysing structural response at each stage of pre-weakening. Our assessments tracked the centre-of-gravity changes throughout the preparation phase, verifying stability under vertical and lateral actions as critical steel members were progressively weakened. Our engineers designed the explosive placement strategy in collaboration with blast specialists, defining failure planes and collapse directions through integrated structural and blast analysis.
This numerical analysis provided assurance for temporary stability during preparation and enabled the spectacular, controlled blow-down in August 2021, with structures collapsing precisely as designed.
We developed 3D finite element models of the chimneys and large suspended boiler/bunker units, analysing structural response at each stage of pre-weakening. Our assessments tracked the centre-of-gravity changes throughout the preparation phase, verifying stability under vertical and lateral actions as critical steel members were progressively weakened. Our engineers designed the explosive placement strategy in collaboration with blast specialists, defining failure planes and collapse directions through integrated structural and blast analysis.
This numerical analysis provided assurance for temporary stability during preparation and enabled the spectacular, controlled blow-down in August 2021, with structures collapsing precisely as designed.
Managing structural stability during demolitions
Managing structural stability during demolitionsSix hyperbolic cooling towers were due for demolition in three phases between July 2019 and March 2022. Each tower needed extensive pre-weakening before explosive demolition, creating temporary structural conditions not anticipated in the original design. The phased approach meant lessons from early demolitions informed our later methodology refinements, while maintaining consistent safety standards across the 250metre exclusion zone.
We conducted finite element modelling for each cooling tower, assessing structural capacity during progressive member removal and verifying stability under wind loading in partially weakened states. Our analysis identified critical support sequences that maintained structural integrity throughout preparation while creating the required collapse mechanism. We developed monitoring protocols to track ground-borne vibration and structural response of surrounding assets during each blow-down phase.
The phased analysis enabled Keltbray to execute demolitions with confidence across three years, with each tower collapsing into its designated drop zone and monitoring data confirming predictions throughout the programme.
We conducted finite element modelling for each cooling tower, assessing structural capacity during progressive member removal and verifying stability under wind loading in partially weakened states. Our analysis identified critical support sequences that maintained structural integrity throughout preparation while creating the required collapse mechanism. We developed monitoring protocols to track ground-borne vibration and structural response of surrounding assets during each blow-down phase.
The phased analysis enabled Keltbray to execute demolitions with confidence across three years, with each tower collapsing into its designated drop zone and monitoring data confirming predictions throughout the programme.
Outcomes
OutcomesThis project demonstrates the value of construction engineering involvement in complex decommissioning works, where innovative methodologies and detailed structural analysis enable safe demolition in constrained environments. Our three-year engagement with Keltbray allowed us to refine approaches across multiple demolition phases, applying lessons from early successes to later challenges while maintaining consistent risk controls.
Key results:
The Ferrybridge C Power Station demolition was completed successfully in 2022. Wentworth's construction engineering knowledge helped deliver predictable outcomes across one of the UK's most complex power station decommissioning projects, enabling the transition from coal generation to the redevelopment of this significant Yorkshire site.
Key results:
- Environmental protection: Sequential jack-down methodology eliminated river contamination risk from barge unloader demolition adjacent to River Aire
- Contractor confidence: 3D finite element analysis of chimneys, cooling towers and boiler/bunker units gave Keltbray certainty that structures would remain stable through extensive pre-weakening operations
- Precision demolition: Controlled explosive placement strategy based on structural and blast analysis, collapsed all structures into pre-defined drop zones as designed
- Programme delivery: Phased structural assessments across 2019-2022 enabled continuous demolition progress with consistent safety standards throughout the three-year programme
- Risk management: Centre-of-gravity tracking and stability assessments at each pre-weakened stage prevented unexpected structural behaviour during preparation phases
- Community safety: Comprehensive monitoring and 250metre exclusion zone protocols protected residential properties throughout multiple controlled blow-downs
- Innovation: Bottom-up jack-down approach demonstrated an alternative to conventional top-down demolition for sensitive riverside structures.
The Ferrybridge C Power Station demolition was completed successfully in 2022. Wentworth's construction engineering knowledge helped deliver predictable outcomes across one of the UK's most complex power station decommissioning projects, enabling the transition from coal generation to the redevelopment of this significant Yorkshire site.