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Saltholme Substation, UK

d² GRP Dura Access Solutions | Case Study

Project: Saltholme Substation, Stockton-on-Tees, UK

Client: Kelvin Power

Electricity substations are an integral component in the power network that allows the safe delivery of electricity to domestic and commercial customers. In this project at Saltholme Substation in Stockton-on-Tees, England, substation design specialist, Kelvin Power (part of the Vinci Energies group) was appointed by main contractor Omexom to supply a number of non-conductive access structures to facilitate safe passage to equipment cabinets.

Our GRP Access Structures are designed and fabricated in-house using proven real-world materials data and analysis for maximum safety.

Kelvin Power turned to long-term partner Dura Composites to design, fabricate and supply six Glass Reinforced Polymer (GRP) structures which allow safe access by authorised personnel. As noted by the general demarcation of the work area using the appropriate coloured and sleeved cones, the Dura Composites Access Structures are located within an area requiring a Limited Access Certificate, meaning they are only accessible by specific personnel who are trained to access to high voltage compounds and routes.

Dura Composites have extensive experience in the provision of GRP solutions for the energy sector including Machine Access, Gantries, Stepovers, Trench Covers and Ladders. Our first-class fabrication facilities at our East of England HQ enable us to construct even the most complex projects safely, reliably and to the highest standards. Choosing a pre-fabricated GRP solution from Dura Composites significantly reduces the man-hours on site and can help to compress a project schedule.

Our latest d² range of products deploy unique patented designs and the latest composite technology to deliver the safest, most cost-effective and durable solutions on the market. Our unique GRP floor gratings are tested to over a million footfalls (to BS7976) and all of our GRP profiles exceed the E23 grade, ensuring maximum performance.

Speaking about the project, a Representative at Kelvin Power commented:

The team at Dura Composites are very adept at understanding our requirements and at using the latest design and fabrication technologies to deliver assets for the energy industry that deliver long term value and are reliable, safe and efficient.


Like us, Dura are certified to ISO 9001 and ISO 14001, demonstrating their commitment to enhancing customer satisfaction through the implementation of integrated management systems. We look forward to working with them again on future projects.

Precision fabrications, engineered to be the strongest and safest GRP structures on the market.

Transitioning towards a low carbon economy, whilst meeting demand

Saltholme was constructed to help fulfil the UK’s need for “fast-start” and flexible power generation during high consumer demand, and was not opposed by the RSPB (who operate the adjacent land owned by Teesside Environmental Trust) on the basis that it “could actually help reduce carbon emissions during the period of transition towards a true low carbon, renewable energy economy by reducing the amount of gas used by large inefficient powerplants designed to be running at full power being used as a stop start backup.”

The use of Dura Composites ‘efficiently designed GRP structural components means each resulting structure is lighter than traditional equivalents, reducing the material embodied carbon, install carbon and delivering a design life of sixty years.

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