Beta Design Consultants provide consulting advice to clients to enable the life extension of structures and assets. We support asset owners in the process of extending the service life of existing buildings, bridges, topsides and jackets of offshore platforms, or other infrastructure beyond their original design lifespan.

Life extension studies involve various strategies, techniques, and interventions aimed at preserving, maintaining, and enhancing the structural integrity, functionality, and safety of the assets.

We have a proven track record based on our experience working with very complex assets in very harsh and challenging conditions. Some of the assets we have advised on include:

Offshore: Fitness for Service, Structural Integrity Management and Life Extension studies for various clients including:

  • ACG-BP Offshore Platforms (topsides and jackets) in the Caspian Sea. Supporting DNV GL in the ad-hoc modifications, weight management and life extension of these platforms.
  • The Structural integrity management service for BG Tunisia (Miskar platform)
  • The Structural integrity management and helideck strengthening for Premier Oil Platform in Trinidad and Tobacco.
Figure 1: Platform structural model built in SESAM Genie converted to USFOS for Non-Linear
Structural Analysis
Figure 2: Shah Deniz I Structural Integrity Management

Onshore: Asset Refurbishment for onshore assets including assessment and repairs/upgrades of roads, drainage, Piperacks. This service was offered on various projects assets on GF Gas Plant Civil and Structural Facilities/Asset Refurbishment. Supporting Bechtel in the inspection, testing supervision, design and refurbishment supervision of various facilities in this Gas Plant located on the coastal area in Alexandria, Egypt.

  • The roads network for the gas plant.
  • The drainage network for the gas plant (rainwater, firewater, foul-water, process water)
  • The oily water sump.
  • The closed process water deep sump.
  • The tanks foundations (diesel tank, firewater tank).
  • The Piperacks and their foundations.
  • Furnace Foundations.
  • Compressor Shelter (Steel Structure).
  • Substation buildings.
Figure 3: BP GF Gas Plant Asset Refurbishment
Figure 4: BP GF Gas Plant Deep Sump Inspection and Repair
Figure 5: BP GF Gas Plant Piperacks and Foundations Assessment
Figure 6: BP GF Gas Plant Heater Pedestals & Foundations Assessment

Bridges: Structural inspection, NDT investigation, structural assessment and repair design for masonry, steel, concrete and composite bridges. This includes specifying repairs and for concrete bridges includes cathodic protection design or corrosion management systems design. Some of these bridges are managed by local authorities while others are privately maintained or managed by the Highways Agency.

  • Henley on Thames Stone Bridge Structural Assessment for revised highway loading
  • Clonarkiety Bridge Structural Assessment & Strengthening Design

Figure 7: Henley on Thames Bridge Structural Assessment

Buildings: Structural inspection, NDT investigation, structural assessment and repair design for various building types including

  • Residential properties (homes, residential purpose-built blocks, tower blocks including large panel system type, non-traditional homes). Our portfolio includes properties for Espom & Ewell council, LB Lewisham, LB Lambeth, LB Southwark, LB Hammersmith and Fulham to name a few asset owners.
Figure 8: Meath House Refurbishment and Non Destructive Testing

Commercial and mixed use properties such as Brindleyplace in Birmingham where we provided the structural strengthening for 60 structural elements that needed intervention.

Figure 9: Brindleyplace Refurbishment
  • Science, health and education properties such as Kennedy Institute (University of Oxford) and Harwell Science Campus Building 150 (Didcot) where we developed a bespoke punching shear strengthening solution and designed high performance concrete jackets for 10 beams to give the building a new life as a Grade A office after it was used as an airmen’s mess. Our portfolio includes properties for the University for the Creative Arts, University of Oxford and London South Bank University.
Figure 10: Harwell Campus Building 150 Life Extension and Conversion
Figure 11: St David Care Home Refurbishment

Car Parks: Beta Design Consultants have demonstrated expertise in the structural inspection, NDT investigation, structural assessment, conversion and repair design for various types of steel and concrete car parks. Our scope includes designing new deck waterproofing systems, specifying repairs and corrosion management or cathodic protection of car parks. In some car parks where loading and structural capacity was an issue, our scope included structural strengthening using traditional methods or using novel materials such as composites (CFRP) or such as high-performance concrete (HPC) as a jacket or as an overlay. 

In one case, Northampton Spire Academy car park for the Ministry of Education (PC MACE), we specified an overlay of 30mm of HPC to get the ramp to work after our structural assessment showed that section loss in rebar caused by chloride attack has reduced its capacity. We also specified a cathodic protection system based on the use of galvanic sacrificial anodes to give the client a 20-year life extension (provided a programme of maintenance and inspection is implemented).

In another case, we inspected a two storey underground car park during the sale of a multi-storey office in Epsom. The condition of the car park was questioned by the inspecting surveyors and our structural inspection and NDT testing confirmed that the condition of the concrete was acceptable. The defects identified related to waterproofing issues in one area of the exposed deck. We worked with a car park repair specialist “Makers” to advise client on repair costs so that sufficient allowance can be made for the repairs during the purchase.

In another case, we advised an asset owner (a port authority), on the management of multiple car park assets and on options for repairs – including waterproofing options, structural strengthening options and solutions for identified defects.

We are constantly supporting clients who are maintaining such assets or converting them and are currently looking at multiple car parks having structural maintenance issues or structural refurbishment plans, including conversion (change of use) or extension (horizontally and vertically).

Industrial & Process Plants: Our expertise on industrial buildings (manufacturing, process) includes some very complex structures subject to various types of equipment and operational loading under extreme exposure conditions (wind, corrosion, operational changes). This is all combined with the need to design repairs so they can be implemented during shut down periods, safely within tight operation budgets. 

Our clients include:

  • Syngenta Huddersfield (previously ICI Imperial Industries)
  • Tata Steel Port Talbot
  • DSM Facilities (Glasgow Darly)

Beta Design Consultants engineers designed the upgrade and advised on the life extension of very complex assets including for Syngenta including Reglone R5, Syngenta Reglone R7.

Beta Design Consultants engineers carried out an assessment for revised loading and strengthening proposal for Deterrer for Tata Steel.

Our engineers are engaged in providing regular maintenance reviews, inspections and shutdown repairs design for multiple clients in the UK and overseas.

Special Structures: our life extension service can be applied to any special structures, including:

  • Ports, wharfs and piers.
  • All types of retaining structures (soil, liquids)
  • Tanks
  • Sculptural and architectural metalwork
  • Towers and masts for telecoms
  • Flare towers
  • Electricity transmission towers
  • Conveyor belts support towers/structures (Mining and Metals)
  • Equipment support structures and foundations

 

Although we have a bespoke approach for each project depending on clients requirements and asset condition, we try to follow a consistent approach to life extension studies:

  • Review of Existing Records (As-builts, previous inspections, maintenance records, loading/operational information)
  • Testing: We advise clients on testing, investigation and NDT requirements based on the asset type. In many cases, our engineers conduct these assessments in house and follow UKAS accredited procedures and use UKAS accredited labs to carry out the testing on material samples.
  • Structural Assessment: It is important to conduct a comprehensive structural assessment as the first step in determining the condition and remaining service life of a structure. This assessment is based on non-destructive testing results, visual inspection findings, and analysis of structural components, existing material condition, and systems. It helps identify any deterioration, damage, or weaknesses that require attention.
  • Repair and Rehabilitation: Based on the findings of the structural assessment, appropriate repair and rehabilitation measures are implemented. These may include repairing cracks, reinforcing weakened areas, replacing damaged elements, and addressing corrosion or deterioration. Techniques like concrete patching, steel reinforcement, and waterproofing can extend the life of the structure and restore its integrity. Other measures we provide advice on include cathodic protection. Our approach is unique in its adoption of traditional techniques (e.g. plating, jacketing, post-installed rebar, steel sections upgrade) as well as novel materials use (use of composites in repairs such as CFRP/GRP, use of high performance concrete HPC/UHPC, use of special grouts, use of FRCM).
  • Maintenance and Upkeep: Regular and proactive maintenance plays a vital role in extending the life of structures. This includes activities such as cleaning, painting, lubrication, and inspection of various components. Timely maintenance helps prevent or mitigate deterioration, identifies potential issues early on, and preserves the structural integrity and functionality of the asset.
  • Strengthening and Retrofitting: Strengthening and retrofitting techniques are employed to enhance the load-carrying capacity, resilience, and performance of structures. This may involve adding additional structural elements, increasing the strength of existing components, or implementing advanced technologies like fiber-reinforced polymers (FRP) to improve structural stability and durability. We have multiple case studies where composite materials were used effectively to solve construction challenges within budget and on time.
  • Corrosion Protection: Corrosion is a common cause of structural deterioration, particularly in bridges and marine structures. Applying protective coatings, using corrosion-resistant materials, and implementing cathodic protection systems can significantly extend the service life by preventing or slowing down the corrosion process. We have implemented such solutions in oil and gas facilities and in car parks as well as in building structures exposed to harsh conditions.
  • Monitoring and Inspection: Implementing a comprehensive monitoring and inspection program helps in early detection of structural issues and enables timely interventions. This can involve using sensors, instrumentation, and advanced monitoring techniques to assess the performance and behavior of the structure. Continuous monitoring allows for proactive maintenance and timely corrective actions.
  • Adaptation and Upgradation: Structures may need to be adapted or upgraded to meet changing needs, standards, or regulations. This could involve modifying the design, adding new features, or incorporating new technologies to enhance functionality, energy efficiency, or safety. Upgrading systems like electrical, plumbing, or HVAC can also contribute to extending the overall lifespan of the structure.
  • Sustainability Considerations: Incorporating sustainable practices in the maintenance and operation of structures can contribute to their longevity. This includes using eco-friendly materials, implementing energy-efficient systems, and adopting green building practices. Sustainable approaches not only extend the lifespan of structures but also minimize environmental impact.

By implementing these strategies, Beta Design Consultants support asset owners to ensure their structures are effectively managed, maintained, and upgraded to extend their service life. Life extension measures not only provide economic benefits by deferring the need for costly replacements but also contribute to the sustainability and resilience of infrastructure assets.