A collaborative team led by React Engineering provides a novel solution to a complex decommissioning challenge, opening opportunities for wider application and developing future industry talent.

A successful engineering trial, led by Cleator Moor based React Engineering, has delivered a breakthrough approach to a decommissioning challenge at Sellafield.

The solution, developed through cross-sector collaboration, can now be applied more widely across the UK’s nuclear estates.

The focus of the project was to seal difficult-to-access openings in the roof of a C5 containment cell. The openings had been left behind by removed pipework used in the production of fuel elements for the Prototype Fast Reactor at the Dounreay nuclear site, in Scotland.

React led the design and testing of the solution, involving the application of a polyurethane spray coating, combined with an intumescent layer that expands under heat to form a robust barrier.

While elements of the technique have been applied in the construction industry, it had not previously been tested or deployed in a nuclear context.

“The success of this project encapsulates so many of the core values of React,” said Phil Redfern, Managing Director of React Engineering.

“In addition to developing an innovative solution to accelerate decommissioning, the trial work has also identified potential future uses in applications such as weather-proofing facilities or fixing surface contamination.

“This will support safe clean-up at Sellafield and other sites.”

React brought together a diverse team as part of the Cumbria Nuclear Solutions Limited (CNSL) partnership.

Protective Coating Solutions (PCS), based in Bury brought deep technical knowledge of advanced coating applications, supporting the development of a safe and reliable system for use in the highly regulated nuclear environment.

Glasscraft, a spray-application company, supplied specialist equipment and insight from outside the nuclear industry, while Cumbrian SME Forth constructed a full-scale test rig at its Flimby facility to simulate real conditions and trial the process ahead of site deployment. “The trial allowed us to work with the client to carry final validation testing to demonstrate the equipment and retire outstanding project risks.”

Phil added: “Collaboration with our clients and colleagues is a touchstone of the work we do at React.

“It was fantastic to bring together experts from different backgrounds and achieve a common goal through shared problem solving.

“While developed to address a specific challenge at Sellafield, the success of the trial demonstrates a safe, adaptable, and potentially scalable method for sealing difficult structures, contributing to the sector’s wider mission of accelerating decommissioning and delivering safe outcomes for the public and environment.”

The project also created a valuable platform for professional development.

Project engineer James Conery played a central role in the project’s delivery.

“Being part of this project has been a great learning opportunity to see an initial concept develop into a fully tested, implementable solution,” said James.

“It has been great for my development as a nuclear professional.”