A site like no other: Overcoming challenges in a nuclear environment

Located on the coast of Cumbria, England, Sellafield began as a pioneering hub for nuclear energy. In 1956, it became home to Calder Hall, the world’s first commercial nuclear power station, marking the start of the UK’s civil nuclear industry. Over the decades, Sellafield transitioned from energy production to nuclear fuel reprocessing and, more recently, to decommissioning and nuclear waste management. With over 200 nuclear facilities spread across 2,630,459 m² – an area roughly the size of 488 football fields – Sellafield is now focused on safely dismantling legacy infrastructure and securing a sustainable future.

The KAEFER-Sellafield Partnership: 15+ years of expertise

For over 15 years, KAEFER has been a trusted partner at Sellafield, providing essential industrial services that ensure safety, efficiency, and compliance. What began with asset care in operational facilities through scaffolding, insulation, and asbestos removal has grown into a much broader scope.

As Sellafield’s needs have evolved over time, the partnership between Sellafield and KAEFER has also expanded, now encompassing a broader range of services. These include technical design, asbestos and hazardous material management, protective coating and surface protection, temporary works coordination, passive fire protection, and project management, to name just a few. Today, more than 280 employees from KAEFER UK & Ireland are working permanently on the Sellafield contract, contributing their expertise to ensure safety, efficiency, and innovation in every aspect of the project.

More than a job – A carefully orchestrated challenge

Sellafield handles the country’s most hazardous radioactive waste. From nuclear waste processing and storage to large-scale decommissioning programs, its mission is to create a safer future for generations to come. This long-term journey requires a careful, step-by-step approach, with full site remediation expected by 2125, as guided by the UK’s Nuclear Decommissioning Authority.

For KAEFER, this means working within some of the strictest safety, regulatory, and operational requirements in the industry. KAEFER UK & Ireland has strengthened its expertise in scaffolding, encapsulation, and environmental controls to ensure every task is carried out to the highest standards.

But what does a day on-site really look like for KAEFER Teams, working in an environment where radiation is an everyday factor?

With specialised sites come specialised requirements – preparation starts long before entering the site.

Employees must go through one of the UK’s highest security clearances (SC and DV Clearances) and complete intensive training before setting foot in high-hazard areas. This training covers everything from emergency protocols and first aid to radiation exposure management – all essential knowledge for working in such a unique environment.

But that’s only the beginning.

Radiation exposure is one of the biggest challenges at Sellafield, and strict time limits dictate how long employees can spend in specific areas. Some zones allow only 20 minutes of work before mandatory withdrawal. To make every second count, KAEFER meticulously plans tasks weeks in advance, coordinating with clients to ensure that the most critical work is completed within the allocated time.

After taking these first steps, the challenge shifts:

The majority of KAEFER’s workplaces at Sellafield are extremely tight on space. Scaffolding and asbestos removal – tasks that ideally require a lot of room to operate – become even more demanding in these confined conditions. But count on KAEFER to make it work.

Some people may wonder what happens to old scaffolding after it has been on a nuclear construction site. Old scaffolding that has been dismantled is regularly checked by KAEFER for contamination and reused if it is proven to be safe. If it is found to be contaminated, it is disposed of via the specified Sellafield waste disposal route.

Beyond the job: KAEFER’s community commitment

KAEFER’s partnership with Sellafield extends beyond the work itself.

Through local employment and training initiatives, KAEFER UK & Ireland supports education, career development, and construction skills training, helping to equip individuals for the future. Under the new-year framework agreement, the KAEFER Team is committed to delivering meaningful social value, including an investment in educational equipment for students with special educational needs and specialised training programmes to attract new talent and bridge the regional skills gap. By empowering the local workforce and fostering growth, KAEFER strengthens the community.

Looking to the future

Every task at Sellafield is a challenge that demands precision, strategy, and teamwork. From navigating small spaces and managing radiation exposure to planning every move weeks in advance – success here isn’t about luck, but about preparation and expertise.

KAEFER UK & Ireland has been mastering these challenges for over 15 years, continually adapting and innovating to best support Sellafield’s long-term mission.

As the site moves into its next phase, KAEFER remains committed to shaping the future of nuclear decommissioning, unlocking new opportunities through technology, expertise and partnership.