Project Overview
Clark-Drain are supporting Kier Group with the ground-breaking construction of the UK’s first carbon-neutral prison, located at the Full Sutton site in the East Riding of Yorkshire. The 1,500-bed Category C “mega” prison will be the first to be zero-carbon in operation, and once built, will run fully on electricity. Other sustainable design features also include solar panels, heat pumps and more efficient lighting systems to reduce energy demand. This collaboration marked the continuation of Clark-Drain’s relationship with the Ministry of Justice, where they have been a trusted partner on other high profile projects such as the multi award-winning HMP Five Wells in Wellingborough which opened in March 2022.
Key Contributions
Clark-Drain partnered with Kier from the specification stages, working collaboratively to deliver the best advice and solutions to meet the demands of this challenging build. Of the 419 access points required to house the extensive electrical infrastructure buried throughout the site, Clark-Drain manufactured and delivered 418 of them.
The heavy-duty access chambers, made from recycled polypropylene, were custom- manufactured at Clark-Drain’s factory in Yaxley, Peterborough. The use of polypropylene not only made the chambers easier to manoeuvre on-site, reducing the need for heavy lifting equipment but also aligned perfectly with the project’s sustainability goals.
Innovative Solutions
Recognising the need to streamline the delivery process, Clark-Drain added small ‘feet’ to each heavy-duty access chamber, raising them slightly off the ground. This innovative feature allowed forklifts to easily slide under each chamber, straight from the lorry or on the ground, speeding up unloading and distribution. This approach completely eliminated the need for additional pallets, massively reducing waste and improving site efficiency. The feet were never removed as they were also found to help with alignment into the designated pits
On delivery to site each chamber was allocated specific codes so their exact location and installation could be managed and monitored. This was critical, as the security access lids and supporting frames had to be installed together with each being an exclusive fit and supplied together to be considered as a single unit. Kier had specified that the lids must be capable of withstanding up to 40 tonnes of pressure, so worked closely with Gatic to deliver the final result.
To support the weight of the lid and frame, concrete surrounds were fabricated on-site. These sat comfortably on the polypropylene access chamber construction. The chambers were pre-drilled offsite, allowing for swift installation upon arrival.
On-Site Flexibility and Support
Given the complex nature of the project, Clark-Drain’s polypropylene chambers offered additional flexibility. If last-minute changes to cabling routes were required, the chambers could be easily cut on-site with standard tools, a feature that proved invaluable.
Clark-Drain were chosen to supply key drainage and access components for the UK’s first carbon-neutral prison at Full Sutton, East Riding of Yorkshire. Delivered by Kier Group, the new Category C facility for 1,500 inmates has now opened and will operate fully on electricity, supported by solar panels, heat pumps and high-efficiency systems to significantly reduce its carbon footprint.
