Bespoke Project: Masterhitch helps with the Royal Sovereign Lighthouse Project

Lighthouse project

At Masterhitch, we’re proud to have been part of one of the most challenging and complex projects in recent maritime history: the deconstruction of the Royal Sovereign Lighthouse, located 8 miles offshore from Eastbourne in the English Channel. Working closely with Robore Cuts Ltd, a leader in diamond drilling and controlled demolition, we’ve helped create a bespoke engineering solution for this lighthouse project, which involves the complete removal of the lighthouse, its accommodation block, and helipad.

Why the Lighthouse Needed to Be Removed

The Royal Sovereign Lighthouse has stood as a vital navigation aid for over 50 years, but due to significant structural deterioration, Trinity House – the UK authority responsible for maintaining lighthouses – determined that the only viable option was to dismantle it. The accommodation block was suffering with delamination of the concrete and it was therefore important to prevent risk of injury to anyone.

Overcoming Unique Challenges

Deconstructing a 27-metre tall, 7-metre diameter structure that’s been standing in the middle of the sea for decades is no simple feat. This project has faced numerous challenges from the outset, not least of which has been the unpredictable British weather. Battling high winds, rough seas, and working against the clock with autumn fast approaching has meant our team has had to be adaptable and ready for anything.

Our involvement began when Robore Cuts Ltd approached us to help design a solution for the main lighthouse column. The project initially focused on removing the top section of the lighthouse, including the helicopter pad and living accommodation. This part of the structure weighed over 400 tonnes and was successfully cut in a single piece using a diamond wire saw before being lifted by a sea crane onto a barge. However, the main supporting column still remained standing, and that’s where we came in.

Lighthouse project
Lighthouse project

Designing the Perfect Solution for the Lighthouse Project

Robore Cuts Ltd needed a way to safely and efficiently cut through the remaining structure, which stretches from the seabed to 27 metres above sea level. After reviewing the options, we designed and fabricated a bespoke steel saw frame capable of fully encapsulating the lighthouse column. This custom design enabled three wire saws to run simultaneously, making the cutting process more efficient while maintaining safety and stability.

We also incorporated multiple platforms into the design to allow for the operation of drilling rigs – two above the waterline and two below. The entire system is remotely controlled to ensure precision and safety, particularly given the offshore location and challenging conditions.

Sean Greene, our Head of Engineering, said it best: “This lighthouse project required a comprehensive solution, and we knew from the outset that it would be a challenge. Our team worked closely with Robore to ensure the design could meet the project’s demands. The result is a frame that not only enhances efficiency but also improves the overall safety of the operation.”

Overcoming Weather Delays

While the lighthouse project design was a success, the weather has been less cooperative. Strong winds and heavy seas initially delayed the installation of the wire saw, and the team had to wait for the right window to proceed. However, with the saw now installed and all equipment in place, Robore is preparing to begin the next phase of the project – wire sawing and diamond drilling for the lifting holes – at the first opportunity.

Despite the weather, the team remains confident that the deconstruction will be completed on time. With the summer behind us and autumn closing in, every day counts, but with our robust solution now fully installed, the lighthouse project is moving forward smoothly.

A Closer Look at the Engineering

The saw frame we designed is truly a marvel. Standing 27 metres tall, the multi-level steel structure wraps entirely around the lighthouse column, ensuring a secure environment for the cutting and drilling operations. It’s made up of several modular sections, allowing it to be reduced in height as the column is gradually dismantled, which helps maintain stability throughout the project.

Safety has been our top priority, and our bespoke framework has provided the stability needed to complete such a challenging offshore project. By creating a stable and secure working environment, we’ve helped ensure that the risks associated with working at sea are minimised, allowing Robore to focus on the delicate task of cutting and dismantling the structure.

Due to time constraints with the weather conditions window becoming smaller a decision was made to cut the top thinner section of the column from inside while the frame was assembled at Shoreham docks. The frame was now only 18.5 metres tall with 8 work levels.

Lighthouse project

Royal Sovereign Lighthouse Project: A Proud Collaboration

Jeff Lawrence, Contracts Director at Robore Cuts Ltd, praised our work on the lighthouse project, saying: “Masterhitch’s engineering expertise has been invaluable. From initial design to installation, the team has shown incredible dedication and innovation to overcome the unique challenges of this project.”

We’re proud of the role we’ve played in this project, and we’re excited to see it progress. Collaborating with Robore Cuts Ltd has allowed us to showcase the strength of our custom engineering solutions, and we’re confident that the Royal Sovereign Lighthouse deconstruction will be a success.

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All information correct as of: 3rd October 2024.