Sizewell C’s Joint MD Nigel Cann on innovating delivery using replication

The construction in Suffolk of Sizewell C nuclear power station is built upon a high degree of standardisation, as the above-ground infrastructure design replicates Somerset’s Hinkley Point C (HPC). Both use proven European Pressurised Reactor (EPR) technology.

This replication offers several compelling advantages, such as risk reduction and predictability, supply chain resilience and regulatory familiarity. Critically, the transfer of knowhow from one workforce to another is projected to result in significant cost and time efficiencies, with £1bn in cost savings already identified through replication and innovation.

The relentless pursuit of ‘better’

While replication provides the foundation of the ‘what’, Sizewell C is not static in delivery (the ‘how’) and the company is constantly striving for material gains.

Innovation is an integrated priority to address specific challenges, improve outcomes and ensure the project is constantly improving. These innovations are primarily focused on the delivery and integration aspects, rather than the fundamental station design. Replication means building on the proven design and the lessons of HPC, but innovation comes in how that replication is applied, refined, scaled and automated.

Construction methodology

Lessons from HPC inform adaptive management approaches at Sizewell C. These include innovations in digital tools, modular construction techniques and project management processes to enhance productivity and avoid delays and cost overruns. Here are just a few examples:

In the use of pre-cast concrete components for civil engineering works, HPC is utilising approximately 10%, whereas Sizewell C is aiming to more than double that. These elements are part of a larger structure – including a number of connected walls and slabs, often creating full rooms – that is constructed away from the workface, offline, and lifted into the building as a complete unit, therefore saving time as multiple elements can be constructed in parallel.
For the off-site prefabrication of the reinforcement cages for HPC’s Unit 1 and Unit 2, the figures are 30% and 40% respectively, while Sizewell C is aiming for greater than 60% across both units.
For the mechanical piping modularisation, HPC is aiming to do approximately 55% offsite welds, whereas Sizewell C’s target is 70%.

Sustainability and waste management

Innovations in sustainability are central to the project’s environmental permits and ISO14001 certification. The project uses recycled concrete from the nearby Sizewell A site and plans for extensive biodiversity net gain measures, including the creation of large nature reserves. An integrated waste management strategy, though subject to regulatory approval, aims to responsibly manage waste and explore potential recycling pathways. Not only is this environmentally optimal, but it also reduces costs and material transport distances, and is thus more efficient.

Energy hub concept

A key innovation at Sizewell C is the plan to be an ‘energy-hub ready’ power plant. This involves exploring off-grid applications to maximise the plant's value, such as harnessing waste heat through cogeneration for industrial processes, hydrogen production or Direct Air Capture (DAC) technology. This innovative approach provides the option of further value for the energy system (e.g. operational flexibility), for society and for the shareholders.

The blending of replication, standardisation and innovation is a delicate balance.

However, Sizewell C’s strategy attempts to manage these tensions by making replication the baseline for de-risking the project technically, financially and with respect to regulation. It does this while using standardisation to drive repeatability, automation and innovation as a targeted tool to optimise construction, reduce costs, enhance sustainability and ensure long-term value to the UK energy system and society.

The ultimate success of Sizewell C will serve as a crucial test case for this integrated approach to mega-infrastructure development and delivery.

Read our in-depth profile of Nigel Cann in the autumn 2025 issue of Project journal. You can also hear him in conversation with APM Podcast on Spotify, Apple Podcasts and more.