DOKA DELIVERS PRECISION FORMWORK SOLUTION FOR MAJOR HYDROPOWER UPGRADE AT LOCHAY POWER STATION
Doka has successfully delivered a highly engineered formwork solution as part of the £70 million refurbishment of Lochay Hydro Power Station in Perthshire, Scotland, helping enable the installation of a new 27MW hydro generator at the renewable energy facility.
The complex project required a bespoke approach to concrete construction, with Doka’s advanced formwork expertise and adaptable Radius Top 50 system playing a critical role in delivering a “millimetre perfect” solution for a challenging generator plinth installation.
Specialist Formwork Supports Major Hydropower Infrastructure Upgrade
The refurbishment project at Lochay Hydro Power Station, being undertaken for SSE Renewables, is focused on modernising key generation infrastructure to improve efficiency and increase renewable energy output.
The hydroelectric facility currently produces approximately 170GWh of renewable electricity annually, with the upgrade expected to strengthen long-term clean energy generation capacity.
At the centre of the works was the construction of a highly complex concrete plinth designed to support a new 27MW hydro generator.
The structure measured 1.5 metres high, featured a 1.5-metre internal radius and a six-metre diameter, while also needing to integrate precisely within an existing operational power station environment.
With generator alignment and load transfer requirements leaving no room for error, contractor TRS Formwork required a formwork system capable of delivering exceptional accuracy while eliminating the need for costly redesign or on-site modifications.
Doka Radius Top 50 Formwork Delivers Precision Engineering
To meet the demanding project requirements, Doka deployed its Radius Top 50 timber-beam formwork system alongside specialist engineering expertise and advanced 3D-led design modelling.
The plinth’s 12-sided corbelled geometry presented a significant challenge, requiring bespoke shuttering capable of accommodating multiple contours, complex angles and seamless integration between new and existing concrete structures.
Doka engineers developed detailed 3D manufacturing and assembly models to calculate precise radii and structural angles before creating custom shuttering forms to exact specifications.
A bespoke connecting plate was also designed to establish a WS10 formwork ring manufactured precisely to the required angle, improving material efficiency while reducing environmental impact.
The Radius Top 50 system’s adaptability enabled pre-assembled components to match the plinth’s intricate geometry accurately, supporting rapid installation and helping maintain the project’s 12-week delivery programme.
Hybrid Construction Strategy Reduces Programme Risk
Doka implemented a hybrid construction approach that combined off-site manufacturing with final on-site adjustments.
Formwork elements were partially assembled off-site before being transported to Lochay Power Station for precise installation and alignment with existing infrastructure.
This approach reduced programme risk, improved installation efficiency and minimised disruption within the constrained operational environment.
The bespoke WS10 ring system and precision-engineered components enabled the contractor to form the required geometry without modification during installation.
Contractor Praises ‘First Class’ Technical Support
Tom Scott, Project Manager at TRS Formwork, praised Doka’s contribution to the successful delivery.
He said:
“What Doka provided us in terms of design, formwork and technical support was first class. The final design worked perfectly without us making any on-site adjustments.”
He added:
“The resulting 12-sided plinth, with its complex corbels and angles, worked to the millimetre. The precision allowed seamless integration between the new plinth and the existing structure while keeping the power station operational and the refurbishment programme on track.”
Advanced Formwork Solutions Driving Infrastructure Delivery
The Lochay Hydro Power Station project demonstrates how advanced formwork engineering, digital construction methods and off-site manufacturing can support complex infrastructure delivery across energy and civil engineering sectors.
By combining bespoke design expertise with adaptable formwork systems, Doka successfully delivered a safe, efficient and highly accurate solution for one of Scotland’s key renewable energy infrastructure upgrades.
For more information visit Doka.com
______________________________________________________________________________________
Michael McDonnell Managing Editor of Irish Construction Industry Magazine & Plan Magazine