Civil Infrastructure

FLI Precast Turns Power Plant Byproduct into Low Carbon Innovation

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Project From Ashes to Concrete: Trinity College Dublin and FLI Precast Solutions Turn Power Plant Byproduct  into Low-Carbon Innovation

 
Date

 

 June  2025
Location

 

 FLI Precast, Co. Carlow
Partners

 

 Construct Innovate, Bord na Mona
Business Sectors

 

 Precast Concrete Manufacturing
Services (Technical Disciplines)

 

 Concrete Science and Manufacturing
Project Objectives/ Outcomes

 

 
  • Utilize biomass ash as a resource:
    Transform the biomass ash byproduct from Edenderry Power Station into a valuable material for concrete production.
  •  Reduce carbon emissions in concrete production:
    Develop low-carbon and carbon-free concrete alternatives by:

·       Partially replacing Portland cement with biomass ash.

·       Completely eliminating Portland cement through geopolymerization using biomass ash and metallurgical slag.

  •  Demonstrate performance and scalability:
    Ensure that the newly developed concrete solutions maintain high performance while achieving up to 51% reduction in carbon emissions, making them practical and scalable for real-world construction.
  • Support Ireland’s carbon neutrality and circular economy goals:
    Align with national sustainability targets by promoting circular economy practices—reusing industrial byproducts in construction—and reducing reliance on high-carbon materials.
  • Foster industry collaboration and adoption:
    Partner with FLI Precast Solutions and other industry stakeholders to pilot, refine, and expand the use of this sustainable concrete technology across Ireland’s construction sector.
  • Advance sustainable construction innovation:
    Set a new benchmark for eco-friendly construction materials and encourage broader adoption of greener technologies through research, development, and demonstration.

 
Our Role

 

 ·       Collaboration on research and development:
FLI Precast worked closely with Construct Innovate and Trinity College Dublin researchers to test and apply the biomass ash-based concrete formulations in real precast concrete products.·       Providing industry expertise and validation:
As a specialist in precast concrete, FLI Precast helped ensure that the developed materials met practical performance standards and could be integrated into existing manufacturing processes.·        Supporting sustainability goals:
The company aligned its corporate vision with the project’s aims by actively participating in the development of sustainable, low-carbon concrete solutions. Their involvement demonstrated a commitment to environmental responsibility and innovation.·       Enabling real-world implementation:
FLI Precast’s participation helped bridge the gap between laboratory research and market-ready products, contributing to the project’s success in demonstrating scalability and practical feasibility. 
Geoscience Ireland Contact

 

 Luke O’Connor

loconnor@flipreacst.com

Photo shows

FLI Precast Manufacturing Facility, Co. Carlow, Group photo with production team, Sara Pavia & Dr. Zehao Lei (Trinity College Professor and Phd student), David McDonnell (Batching & Lab Manager, FLI Precast) & Luke O’Connor (FLI Precast Chartered Structural Engineer)

 

Mincon DTH Waterhammer & Spiral Flush Casing System

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Location: Ireland and Scotland

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Templemore Flood Relief Scheme

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Project River Mall Flood Relief Scheme
Date

 

 2017-2024
Location

 

 Templemore, Co Tipperary, Ireland
Client

 

 Office of Public Works (OPW)
Business Sectors

 

 Civil and Environmental Engineering
Services (Technical Disciplines)

 

 Feasibility and Environmental Studies, Project Design and Implementation
Project Objectives/ Outcomes

 

 

 Diversion of the existing River Mall in Templemore town along a newly created river channel (through greenfield and brownfield sites) approximately 850m in length. The Scheme design also included for the construction of several field and road culverts, embankments and widening of the existing river channel. This project saw the inclusion of approximately 160 individual biodiversity enhancement components in the Scheme.

The Project won the Environmental Engineering Project on the Year at the Engineering Excellence Awards in October 2024
Our Role

 

 TOBIN worked closely alongside the OPW throughout this project’s lifecycle from assisting with the initial feasibility studies, completing various environmental assessments, completing an Environmental Impact Statement (EIS) and Natura Impact Statement (NIS), undertaking public and statutory consultation, preparing detailed engineering designs and more recently as Ecological Clerk of Works throughout the multi-year construction phase (2017-2024).

 
Geoscience Ireland Contact

 

 Allison Murphy Allison.Murphy@tobin.ie

 

Supervision of Design/Build of Sumbawanga – Matai – Kasanga Port Road (112km)

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Project:

Supervision of Design/Build of Sumbawanga – Matai – Kasanga Port Road (112km)

Location:

South West Tanzania, Lake Tanganyika Region, Tanzania

Client:

Government of the United Republic of Tanzania

Business Sectors:

  • Roads

Services (Technical Disciplines):

  • Construction Supervision

Project Objectives/Outcomes:

Consultancy services for supervision of the upgrading of 112km of gravel trunk road to bitumen standard under a Design / Build contract under FIDIC Conditions of Contract. The main construction constituents of the road include: Double surface dressing treatment (20mm and 10mm chips); 150mm thick crushed rock base course; 200mm Class C1 stabilized sub-base natural gravel; 150mm thick G:15 natural gravel sub-grade layer; various new bridges, box culverts and pipe culverts. Supervision of Matai Town Roads urban construction included, pavement, relocation of utilities, town drainage, footpaths.

Our Role:

  • Preliminary Design Review
  • Detailed Engineering review of Design and Documentation
  • Topographic Survey and Hydrological Review
  • Site meetings
  • Construction cost control and financial forecasting
  • Material testing and QA control
  • Measurement and IPA evaluation
  • Drainage culverts/structures
  • Detailed project reporting
  • Implementation and Management of project Q/A system throughout the contract
  • Construction Supervision Services
  • Progress Monitoring, Financial Management, and Claims Management
  • Final Measurement of completed Works and Provisional and Final Acceptance of Works
  • Construction supervision and contract administration under FIDIC Conditions of Contract as the “Engineer”
  • Supervision of Matai Town Roads (Urban)
  • Supervision of maintenance activities after construction for 36 months.

Geoscience Ireland Contact: Michel Davitt – mdavitt@nodwyer.com

FLI Water WWTPs – Co. Wicklow

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Project:

MEICA and Civil works including Precast Concrete Tanks for a bundle of WWTP in Co Wicklow

Date:

2016-2018

Location:

County Wicklow

Client:

Irish Water & Wicklow Co Co

Business Sectors:

Water MEICA & Civil Infrastructure

Services (Technical Disciplines):

FLI Water completed refurbishment works at Kilpedder, Kilcoole and Redcross WwTP Co Wicklow as part of a 3 bundle upgrade works for Irish Water. The work consisted of the assessment, design, supply, installation, testing and commissioning of a range of Mechanical, Electrical, Instrumentation, Control and Automation.

Project Objectives/Outcomes:

All three projects required a diverse range of upgrading, to achieve compliance and meet increased capacity flows. In each site, FLI Water and its subcontractors undertook all electrical, mechanical, automation/control, building, civil engineering work, and any other work necessary for the successful completion, commissioning, and testing of the finalised work.

Our Role:

Design, Manufacture and Installation, test and commissioning involving several subcontractors

Geoscience Ireland Contact: mflynn@fli.ie

Mincon – Crown Bridges Light Rail Project, Heksinki, Finland

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Project:

Crown Bridges Light Rail Project

Date:

2021-2027

Location:

Helsinki downtown to the expanding suburbs of Laajasalo and Kruunuvuorenranta,

Client:

City of Helsinki, YIT Suomi Oy, NRC Group Finland Oy, Ramboll Finland Oy, Sweco Finland Oy and Sitowise Oy. The contractors for the overall Crown Bridges contract are YIT Suomi Oy and Kreate Oy.

Business Sectors:

Civil & Geotechnical Engineering

Services (Technical Disciplines):

Drilling in sensitive and complex ground conditions comprising steep topography, granitic rock and soil embankments; deployed M-Wall ring bit casing system  using patented Spiral Flush technology, allowing control of  high pressure DTH drilling in sensitive ground conditions.

Project Objectives/Outcomes:

The Crown Bridges Light Rail (Kruunusillat) project is one of the biggest infrastructure projects in Finland in recent years. When the projected is finished in 2027, a total of three new bridges, including a 1,200-metre-long bridge that will be the longest one ever built in Finland, will connect Helsinki downtown to the expanding suburbs of Laajasalo and Kruunuvuorenranta, shortening the travel distance from 11 km to 5,5 km. This new scenic route is designed for light rail and pedestrians only, encouraging people to use public transport and travel by bicycle.

Our Role:

Construction started in 2021 and Mincon’s drilling expertise has played a significant role, using Mincon’s patented Spiral Flush technology.

Geoscience Ireland Contact: christovangemert@mincon.com

Mincon plc

Dam Site Investigation by Mincon in Finland

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Project:

Melo Dam Renovation

Date:

2022

Location:

Melo Hydroelectric Powerplant, near Noika, Finland

Client:

PVO-Vesivoima Oy & KFS Finland

Business Sectors:

Civil & Geotechnical Engineering

Services (Technical Disciplines):

Drilling in sensitive and complex ground conditions comprising steep topography, granitic rock and soil embankments; deployed M-Wall ring bit casing system  using patented Spiral Flush technology, allowing control of  high pressure DTH drilling in sensitive ground conditions.

Project Objectives/Outcomes:

Successful remediation of water seepage through the 140m long dam using a watertight steel pipe-pile wall.

Our Role:

Specialist drilling and piling contractor ; geotechnical collaborator

Geoscience Ireland Contact: christovangemert@mincon.com

Mincon plc

NICHOLAS O’DWYER – Lusaka to Ndola Dual Carriageway, (T002/T003)

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Project

Design Review of Approximately 321km of the Lusaka to Ndola Dual Carriageway, (T002/T003) including bypass roads in Kabwe and Kapiri Mposhi and 45km of the Luanshya-Fisenge-Masangano Road

Location

Lusaka – Ndola, Zambia

Client

National Road Fund Agency

Business Sectors

Roads

Services (Multidisciplinary)

  • Preliminary Design

Our Role: 

  • Review of previous designs
  • Field investigations
  • Review of Design of Main Contractor

Project Objectives/ Outcomes

The project section of the Road starts from Lusaka and stretches an estimated distance of 321km to Ndola. The project also covers works for construction of bypasses in Kabwe and Kapiri Mposhi and the construction of the Luanshya to Fisenge to Masangano Road. The road section is now earmarked for upgrading to bituminous standard.

 

Geoscience Ireland Contact | Michel Davitt <mdavitt@nodwyer.com>

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Rossaveal Deep Harbour

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Specialist offshore engineering and design consultancy, Gavin & Doherty Geosolutions Ltd (GDG), with their specialist dredging sub consultants, Anthony D Bates Partnership (ADBP), have been appointed by the Department of Agriculture, Food and the Marine (DAFM) to undertake the detailed design, tender and construction phases of the Rossaveel Deep Water Quay Development, at Rossaveel Fishery Harbour Centre (FHC), Co. Galway.

Rossaveel FHC is located on the north-east shore of Cashla Bay, approximately 40km west of Galway city, serving the fishing fleets that operate off the coast of Galway. The existing harbour at Rossaveel is constrained, as no deep-water facilities are currently available to accommodate modern fishing vessels, which continue to increase in size as the industry trends towards larger and more sophisticated boats. To address this, the construction of a new 200m long quay and associated dredging to provide -10m CD on berth (Chart Datum) and -7m CD in the navigation, has been agreed. A reclamation area will also be constructed directly behind the quay, which will provide connectivity from the quay to the existing onshore facilities at the harbour. The development of the harbour infrastructure will attract additional vessel activity and therefore create local employment opportunities in rural Ireland.

Project

Rossaveal Deep Harbour

Location

Co Galway

Client

DAFM

Business Sectors

Marine Civil Infrastructure

Services (Technical Disciplines)

  • Civil, Structural and Safety

Project Objectives/ Outcomes

Appointed design consultants, following initial conceptual engineering phase.

Our Role

GDG’s role has included the preparation of a peer review report, aimed at providing alternative concept design options, analysis of the wave climate and loading conditions and associated ship navigation simulations, optimisation of dredge volumes, and general development of an efficient conceptual design for the deep-water infrastructure. ADBP has provided technical and contractual advice relating to the dredging aspects of the scheme.

Geoscience Ireland Contact: pdoherty@gdgeo.com

Geospatial Services for UK House, London | Murphy Geospatial

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Project

Geospatial Services for UK House, London

Location

London, UK

Client

Blue Sky Building

Business Sectors

Civil Infrastructure

Services (Technical Disciplines)

  • Aerial / UAV Surveys
  • BIM
  • Laser Scanning
  • Property Consultancy
  • Inspection

Project Objectives/ Outcomes

The UAV survey was undertaken by our Specialist Engineering Services (SES) team due to its prominent central London location and the requirement to fly as close to the building as possible. By undertaking a comprehensive UAV flight at close range (in line with all necessary UAV legislation and OH&S requirements), high-resolution imagery could be collated and inspected by our in-house Building Surveying team to provide a detailed Schedule of Condition Report.

In addition, the survey was undertaken to produce a full, accurate, and detailed scan-to-BIM model of the building facades in Autodesk Revit. Undertaken by the Digital Engineering team, the modelling was to be used by the architect, lighting designer, and various other project stakeholders to plan and refurbish the building.

Our Role:

Murphy Geospatial was commissioned to undertake various geospatial services at UK House, a landmark heritage building on the North side of Oxford Street, London.

The primary brief of the project was to undertake a UAV/drone survey of the building roof and facades for the dual purpose of condition reporting and accurate as-built BIM modelling.

Results:

By federating and updating the client’s existing survey and design information into a common BIM environment, Murphy Geospatial provided a singular BIM model of the building externals for all stakeholders to work from.

Geoscience Ireland Contact | Jonathan Butler at jbutler@murphygs.com or Andy Kitson at akitson@murphygs.com or call +44 203 598 3775

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