Roof Replacements with CCL

About this site.

Situated at the Parley Waste Management Facility on Chapel Lane near Christchurch, this £15.6 million anaerobic digestion plant is a major development in Dorset’s renewable energy network. Operated by Eco Sustainable Solutions Ltd, the facility has the capacity to process up to 70,000 tonnes of food and organic waste per year, producing around 60 GWh of biomethane for injection into the national gas grid.

By converting local household and commercial waste into renewable gas and nutrient-rich fertiliser, the site supports Bournemouth, Christchurch and Poole’s circular economy strategy, cutting landfill dependency and lowering regional greenhouse gas emissions. Once fully operational, the plant will generate enough renewable gas to power roughly 5,000 homes annually, while delivering a strong local sustainability benefit.

What we did.

ConstructionCrew Ltd was responsible for the installation and commissioning of all membrane roof systems across the main process tanks. This included the two primary digesters, the hybrid end store and the two pre-storage tanks.

The two pre-storage tanks each measure 9.98 metres in diameter and 6.3 metres high, providing a combined buffer capacity of 938 m³. These steel tanks are fitted with covered roofs and linked to an emissions abatement system to prevent odour and gas release during filling.

The two stainless-steel digesters are significantly larger, each with a 28.41 metre diameter, standing 12.5 metres high including the dome, and holding 5,039 m³ of substrate. Both are fitted with double membrane gas roofs designed to provide 1,550 m³ of biogas storage per tank, complete with gas level indication straps, pressure and vacuum relief valves, and integrated gas balancing systems. The hybrid end store matches this specification, ensuring uniform performance across all three main structures.

CCL’s team managed the full installation, including anchor ring preparation, membrane fitting, tensioning, blower integration and final pressure testing. Leak checks and calibration of the pressure control system were carried out to the manufacturer’s specifications, guaranteeing reliable gas containment and long-term operational stability.

Sustainability & Regional Impact.

The roof installation required close coordination between CCL, other teams on the site from companies we worked with like Weltech. With multiple trades working simultaneously on site, precise timing and communication were essential. CCL worked alongside civil and mechanical teams to align membrane interfaces with tank penetrations, mixers, and pipework routes.

Despite challenging site access and strict programme targets, the work was completed efficiently, with all quality documentation and sign-off delivered in line with the client’s requirements. The project demonstrated the value of CCL’s hands-on, specialist approach to large-scale biogas infrastructure.

Partnership & Collaboration.

The Parley facility will transform up to 70,000 tonnes of Dorset’s food waste each year into renewable biomethane and organic fertiliser, directly displacing fossil fuel use and supporting local farms. By securing the digesters with high-integrity double-membrane roof systems, CCL helped ensure maximum gas capture, pressure stability, and emission control.

Every cubic metre of gas retained contributes directly to renewable energy production, making the membrane roof systems a key factor in the plant’s efficiency and environmental performance. The result is a resilient, low-emission facility that will play a leading role in Dorset’s transition toward a cleaner energy future.