Halley Workshops [ Courtesy British Antarctic Survey ]

© Kalliope (UK) Ltd

Our design and practical experience over the past 12 years in designing and constructing bespoke units for various projects for BAS on Antarctica was important in their Tender evaluation, and we were delighted to have the opportunity of working closely with their Engineering Team in the final design of these unique units, which will experience some of the harshest conditions on earth, with ultra low temperatures and high speed surface winds.

The engineering expertise of our specialist Fabricators in Liverpool, working under direct supervision by our Engineering Consultant, was also vital to the successful manufacture and ease of site assembly in the extreme working conditions. (Illustrated on the following Video is a pictorial record of the assembly process, and moving of the completed Workshops to their final operating location adjacent to the Halley 6 Research Station).

The completed workshops

Specification Notes


Due to shipping and maximum landing weight restrictions, the units were constructed from specially modified ISO Hi-Cube Shipping Containers, which were also Type Certified by Lloyds Register (after a full and rigorous Test Rig programme at their Laboratories - see image below) to enable the units to be shipped on commercial Container Ships.

BAS WAS As Built Layout Drawing

MODULE 1 – (WAS 01 to WAS 08)


WAS – 01 Plant and Mechanical Stores

WAS – 02 Workshop

WAS – 03 Workshop

WAS – 04 Office

WAS – 05 Store

WAS – 06 Heavy Workshop

WAS – 7 Heavy Workshop

WAS – 08 WC/Cleaners


MODULE 2 – (WAS 09 to WAS 16)


WAS – 09 GA Office

WAS – 10 Clothing Store

WAS – 11 Store

WAS – 12 Store

WAS – 13 Workshop

WAS – 14 Workshop

WAS – 15 Workshop

WAS – 16 Workshop

Time-lapse movie of project fit

Kalliope submitted a successful Tender in June 2012 to complete the engineering design and manufacture the Container Units required for the Engineering Workshops required to support the new Halley 6 Research Station, based on the concept design drawings prepared by the British Antarctic Survey (BAS).

Senior visitors to Halley VI all commented that within the units there was no feel of being in shipping containers, all being impressed with the effective use of resources to deliver the project.

Quote from a BAS representative

Lloyds Test Rig

After the extensive structural alterations the units were fitted out to the following specification:


Insulation: The specification for Thermal Resistivity on External Walls, Floors and Roofs required the installation of SOLITEX XR4000 140mm thick Insulation and ROCKWOOL RW3 50 mm thick Insulation on Inner/Shared Walls.


Wall Cladding: Units WAS 001, 004, 005,008, 009, 010 and 012 were Factory fitted with Internal Walls clad using 9mm Balanced Plywood Sandwich Board with 0.9mm ZIMTEC Plastic Coating to one side and 0.9mm Steel to the other side.


Units WAS 002,003, 006, 007, 013, 014,015 and 016 were fitted with Internal walls clad with 9mm Plywood Sheet.


Jointing: All units were supplied with standard ISO Corner Castings, suitable for connection to the Support Platforms shown on the video.


Containers that had the sides partially or completely removed were fitted with a gasket jointing system that sandwiched and compressed between the angles framing the apertures, and rubber 'T' section jointing were supplied for site assembly. The void between the two rubbers was filled with insulating foam during the site assembly location.


Doors: 'Butcher' style Freezer Doors were installed to all External Entrances.


Windows: Triple Glazed Windows with North European Redwood Frames and Powder Coated Aluminium Cladding to BS 6496: 1984 were fitted, including "Glace Solar" glass.


Roof: A specially designed, effective Joint Sealing System complete with allowance for the site injection of Expanding Foam Insulation was manufactured to ensure a fully sealed joint system between assembled units.

Delivery vessel

Above: Assembled modules

Left: Internal view