A Scottish engineering and construction firm has completed work on a project 8,000 miles away, it's furthest away contract so far.

Forres-based AJ Engineering & Construction Services was appointed to create a steel platform which will be installed on Bird Island, South Georgia in Antarctica.

However, due to the job's remoteness, the company had to carry out a mock-up of the installation in its work yard with contractors BAM Nuttall.

The three-month project involved fabricating over 600 individual pieces which have now been shipped to Bird Island. The items will take around two weeks to arrive at their destination ready for installation by BAM Nuttall team.

Overall, the new platform is part of the modernisation of the Bird Island Research Station, an important centre for research into bird and seal biology.

A few challenges were encountered on the project due to sensitivities of the island, as AJ Engineering's quality manager Jazmin Kellas explained: "I have been working with Allan Martin our project manager for the contract and it has been absolutely fascinating.

"The fact that it is 8000 miles away and is so remote is interesting enough, but due to the unique bio-diversity of the island we have had to rethink about how we package the items we are sending over there. The island has been largely untouched by the outside world and the researchers there understandably want to keep it that way.


"Normally we package things using polystyrene or cardboard, however both of these materials are a big no, no. Cardboard can harbour foreign objects such as seeds and the polystyrene can break off. We have had to adopt new methods to ensure that each of the 600 items arrives unscathed. Bubble wrap has been one of the solutions."

Ms Kellas added the AJ Engineering team also had to work with BAM Nuttall to demonstrate how the sections of the platform fit together.

She continued: "Whilst we often handle installation for our clients, for this project it's just not practical.

"This is a long term project and we can't have a team out there for six months. So instead, our installers worked with BAM Nuttall in the yard showing them how the platform fits together. There is no room for error as once it's all out there, the teams are pretty cut off.

"We have also been extremely thorough about the items in the shipment. Once the consignment leaves Forres it will take over two weeks for it to reach Bird Island predominantly by cargo ferry. If we forget to pack something, then the whole project could be held up."

The steelworks were galvanised by Elgin-based Highland Galvanizers who have specialised in structures for remote locations previously.

Highland Galvanizers' Development Director, Geoff Crowley, said: "The island's isolation and small population mean that low maintenance designs are essential, but the steel frame must be protected from corrosion and the harsh environment. For the Bird Island project we used hot dip galvanizing as the steel protection system.

"We have experience of working for isolated places and have galvanized steel for St Kilda and the Falkland Islands and Tristan da Cunha. The coating should give the steel a maintenance free life of over 50 years in Bird Island's severe climate."

Image: Project manager Allan martin and quality manager Jazmin Kellas with the consignment which is now making the 8000-mile journey to Bird Island (credit: Chit Chat PR & Digital)