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Rassau Synchronous Condenser, Blaenau Gwent, South Wales

GRP Trench Covers, Grating, Handrailing & Access Structures

Project: Rassau Synchronous Condenser, Blaenau Gwent, South Wales

Client: Siemens Energy in collaboration with Welsh Power, Quinbrook, National Grid ESO and Western Power Distribution

Work to construct one of the UK’s first grid stabilisation facilities began in 2020, at a new site in South Wales. The project marked a major milestone in the quest to achieve a net zero carbon energy system, and was the result of a collaboration between Welsh Power, Quinbrook, National Grid ESO, Siemens Energy and Western Power Distribution.

Siemens Energy were appointed to design, manufacture, install and commission the site, working with CLS Civil Engineering. Construction was completed in February 2022, with Dura Composites’ solutions specified by expert Consulting Civil & Structural Engineers, Patterson Reeves & Partners.

Now under the management of Welsh Power, the substation features a synchronous condenser and flywheel to provide inertia to strengthen the grid, ensuring that stability can be provided without any power being generated – ultimately meaning that more renewable power can be used on the network.

CLS Engineering and Patterson Reeves & Partners chose Dura Composites to design and supply a range of low weight but high strength non-conductive GRP trench covers, key clamp handrailing, access platforms and screening – all fabricated from the company’s market-leading range of safer, stronger, faster and proven GRP solutions.

With extensive experience in supplying the UK Energy Sector, Dura Composites solutions include Machine Access, Gantries, Stepovers, Trench Covers and Screening. Our products are unique in the market and provide major cost savings versus traditional materials such as concrete and steel, due to their more economical transportation, handling and on-site fitting.

Suitable for use in high-risk areas, our GRP does not conduct electricity or necessitate the use of hot works permits and provides a safe on-site working environment for engineers and maintenance personnel.

Specialist fabrication, cutting and routing takes place at Dura Composites’ East Anglian HQ and as was the case with this project, our services can be used to reduce man-hours on site or compress a project schedule.

Commenting on the successful project, Ben Cartwright, Procurement Manager at CLS Civil Engineering said:

This is a ground-breaking project for Wales and the UK, using innovative, world-class technology as well as local specialists and contractors.

Innovative ideas and thinking are crucial to maintaining the stability and security of energy supplies, and Dura Composites offered an excellent product range and exceptional design support through all stages of this project.

We are delighted to have seen this critical infrastructure project go from concept to successful operation in just two years.

Unlocking the Power of Composites® for Power and Energy Projects:

As the UK’s electricity network continues to move away from large-scale carbon emitting sources towards alternative renewable generation, it faces new challenges. The intermittent nature of renewable sources such as wind power make it impossible for the grid to accurately predict how much energy they will have at their disposal at any one time.

Projects such as the Short Term Operating Reserve (STOR) plants help give the grid the extra flexibility it needs to meet peak demands at short notice and ensure smooth and efficient operation. As projects like this demonstrate, adopting new technologies, processes and solutions within the network is crucial to enabling an energy system that’s fit for the future.

GRP composites can provide major design flexibility, time saving benefits and significant lifecycle advantages over traditional materials such as concrete, and recent clarification of key standards areas such as fire performance have made them more accessible than ever. Applications for our GRP within the Energy Sector include GRP flooring, handrails, trench covers, up and over staircases, utility screening and roof walkways.


Discover the benefits of d2 Dura Grating

Dura Grating Standard Mesh
26mm, 38mm & 50mm

Dura Grating Mini Mesh
23mm, 35mm, 45mm & 55mm

Dura Grating Micro Mesh

Dura Grating Solid Top
29mm, 41mm & 53mm

Designed, developed and manufactured by Dura Composites, d2 Dura Grating offers outstanding safety, performance and durability and is more cost-effective than traditional GRP grating in almost every scenario. It can be applied in all industries where GRP mesh grating is used today and has an industry-leading Class Bfl-s1 fire rating as standard in accordance with BS EN 13501 (excludes 23mm). As with all our grating, it can be supplied with a range of stainless steel clips, clamps and hold down fixings to suit all install scenarios.

A comprehensive range of load testing data is also available within our searchable Online Product Selector database to help you make decisions based on real data to ensure maximum safety for your project.

Why Choose Dura Composites for your Fabrication?

Our fabrications are constructed from the latest GRP composite product design, technology and manufacturing techniques known as the d2 product range. Heavy duty, non-conductive, non-corrosive and chemically resistant access structures fabricated in the UK to provide a safe, cost-effective and durable alternative to steel.

We have supplied fabrications to a wide range of demanding environments including the UK defence sector, water industry, power generation industry, rail, electrical, manufacturing, and materials handling sectors.

Services available in-house include:

  • Finite element analysis
  • Engineering calculations
  • Design optimisation
  • Design troubleshooting
  • 2D and 3D designs
  • CNC cutting
  • Drilling
  • Off-site assembly

Find Out More >>

GRP Products

Product Guide

d² GRP Access Structures | Standard & Bespoke Fabrications


Our Industrial Team

For your industrial and commercial projects, don’t hesitate to contact our GRP experts, who possess the knowledge and experience to deliver exceptional solutions tailored to your specific requirements. Get in touch on 01255 440290

Joe Hunt

Sales Manager

Ian Dennis

Sales Key Account Manager

Danielle Lewis

Sales Account Manager