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Sambar BESS Container Repairs

Project Location:

Cornwall

Client Name:

GE Sambar BESS

Project Description:

OCU was engaged to deliver urgent structural repairs to multiple battery containers at the Sambar Battery Energy Storage System (BESS) site following the identification of corrosion and mechanical damage during routine inspections.


The priority was to restore full structural integrity while maintaining operational continuity and ensuring compliance with safety and engineering standards. Working in a constrained layout around live infrastructure, OCU coordinated specialist lifting, fabrication and welding teams to complete the works safely and efficiently.

Key Stats:

  • Structural repairs to multiple BESS battery containers

  • Zero disruption to adjacent live systems

  • Precision lifts completed within restricted access areas

  • On-site steel replacement and protective recoating

3 Weeks

Duration

Challenge

  • Restricted access within a tightly configured BESS layout, limiting crane use and manoeuvrability

  • Compromised container structure, including corrosion and external damage sustained during offloading by initial contractor

  • Live adjacent systems requiring repairs to be planned and executed without operational interruption

  • Safety-critical environment with high-voltage equipment requiring strict handling protocols

Solution

  • Coordinated specialist lifting teams to deploy hydraulic gantry systems and compact cranes for controlled lifting and repositioning

  • Enabled safe access to damaged units without removing containers from site

  • Mobilised certified fabrication and welding specialists to undertake on-site structural assessments and steelwork repairs

  • Replaced damaged sections, restored structural integrity, and applied protective coatings to prevent future corrosion

  • Maintained close communication with site operations teams to sequence works safely around live systems

Outcome

  • Structural integrity fully restored across all affected BESS containers

  • Works delivered safely with no impact on adjacent operational systems

  • Access and lifting challenges resolved through bespoke engineered solutions

  • Protective coatings extended asset lifespan and reduced long-term maintenance requirements

  • Effective collaboration between OCU, site operations teams and specialist contractors ensured efficient delivery and full compliance with safety and engineering standards

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