New ICF Manufacturing Facility – Barnsley, South Yorkshire

When our client, a US-based manufacturer, set out to develop a new insulated concrete form (ICF) manufacturing facility in Barnsley, South Yorkshire, the objective was clear: create a modern production environment capable of supporting future growth, increased manufacturing capacity and long-term operational efficiency. The project involved the installation and commissioning of a new ICF manufacturing plant, designed to produce and store ICF blocks for the UK market, with the scalability to serve wider European demand in future.

We were appointed to deliver this multi million pound business CAPEX project through a combination of infrastructure upgrades, specialist installation works, utility improvements and production-line integration across the facility. Our scope of works included:

• Project scope development
• Detailed manufacturing plant layout
• Programme management across mechanical, electrical and civil disciplines
• Budget proposal and cost control
• CDM management and control
• Design coordination
• Detailed project plan and Gantt chart, including critical path
• Regular progress reports and scheduled progress meetings
• Factory and site acceptance testing (FAT / SAT)
• Commissioning

Project at a glance

• Location: Barnsley, South Yorkshire
• Project value: 10-20 million (business CAPEX)
• Programme: 19 months / 412 working days on site
• Contractors coordinated: 95+ multidisciplinary contractors
• Safety record: Zero lost time accidents, injuries and no RIDDOR reportable incidents
• Disciplines: Civil, mechanical, electrical, process and commissioning

Preparing the facility for installation

The works began with early-stage planning, engineering assessments and infrastructure reviews, including structural assessment, licence-to-alter submission and coordination with multiple contractors to ensure the project could progress safely and efficiently. Ground inspection and assessment were carried out prior to excavation. Service routing, temporary works and access planning all formed part of this initial phase, creating the foundation for the large-scale installation works that followed.

The works included the removal and demolition of internal factory structures to create additional operational space and prepare the facility for future upgrades. This involved the safe dismantling of two full-height internal walls, along with the associated office, canteen and welfare areas within the main production space. A full strip-out of existing electrical services was carried out, including the isolation and removal of busbars, distribution circuits, cable containment, fire alarm devices and power supplies serving the affected areas.

Essential services connected to the tank farm installation were carefully isolated and left in a safe condition to maintain operational continuity. Mechanical and electrical services were also decommissioned, including the removal of:

• compressed air systems
• gas supply pipework
• water services and associated equipment
• factory gas heaters, flues and destratification fans
• electrical supplies

Existing compressors were isolated and retained on site for the client’s use, while redundant pipework and services were safely removed. The demolition package included the removal and disposal of all associated materials from the walls, welfare block and internal structures, with all waste managed through approved disposal routes. Works were completed using specialist labour, plant and access equipment, ensuring safe and efficient delivery while preparing the facility for its next phase of development.

Civil works and infrastructure modifications

As part of the facility expansion, we delivered a wide range of specialist civil engineering and infrastructure works to support the new manufacturing systems and essential process equipment. This work played a key role in the wider upgrade programme, helping to increase production capacity, improve operational efficiency and prepare the site for future growth.

Water treatment infrastructure

One of the main elements of the project was the construction of a bespoke reinforced-concrete water treatment pit to support critical manufacturing processes on site. The works included full structural design, reinforced-concrete detailing, waterproofing systems and temporary-works engineering to create a durable and reliable below-ground structure.

The project involved deep excavation to approximately 4.5 metres, along with the removal of existing concrete slabs, soil and site drainage. The works were carried out using a combination of:

• confined-space working
• specialist shoring systems
• reinforced-concrete base slabs
• integrated sump pits
• reinforced retaining walls
• central dividing walls
• pipe penetrations and service interfaces
• high-performance waterproofing systems

Robust safety measures were implemented throughout, including gas monitoring, rescue systems, engineered access platforms and temporary support structures.

HV / LV power infrastructure works

Specialist civils and enabling works were also completed to support the installation of a new HV / LV transformer infrastructure package as part of the site’s wider power upgrade. Works included:

• construction of reinforced-concrete transformer bases
• HV cable trenching and service routes
• utility coordination works
• installation of secure palisade fencing
• controlled access systems
• groundworks associated with substation integration

These upgrades provided the facility with safe, scalable and future-ready power infrastructure capable of supporting increased production demands and future automation systems.

Site drainage

Additional civils works were carried out to install new drainage infrastructure serving the boiler plant, compressor room and pre-cut manufacturing areas linked to the new ICF ancillary process systems. The scope included excavation, reinforced-concrete construction, structural coordination and the installation of specialist below-ground drainage pipework integrated into the wider manufacturing process infrastructure.

Outcome

The completed civils works demonstrated our expertise in complex industrial civil engineering, reinforced-concrete construction, utility coordination and deep excavation. The finished infrastructure package now provides the ICF manufacturing facility with a robust platform to support continued operational growth, increased capacity and long-term expansion of its UK production operations.

Heavy equipment handling and specialist installation

One of the most technically challenging stages of the project involved the unloading, internal transportation and final positioning of large-scale manufacturing equipment within restricted factory areas. Working within confined operational spaces meant that traditional lifting methods were not always practical or suitable. To overcome this, specialist lifting and rigging solutions were used to safely manoeuvre heavy production machinery into position without disrupting surrounding operations.

The works involved compact lifting equipment, controlled skidding systems and precision positioning techniques specifically selected for space-restricted industrial environments. Every movement was carefully planned and coordinated to ensure the safe installation of critical manufacturing equipment while maintaining programme efficiency across adjacent works. This phase highlighted the importance of detailed logistical planning, technical lifting expertise and safe execution within live manufacturing environments.

ATEX ventilation and insulation works

As part of the expansion works, we delivered a specialist ventilation and process-safety system to support the new silo production area and associated manufacturing operations. The project included the design, supply, installation and commissioning of a bespoke supply-and-extract ventilation system, engineered to maintain the required air-change rates while safely removing the low-level pentane gas generated during the manufacturing process. The solution was designed with a strong focus on safety, compliance, energy efficiency and long-term operational reliability.

The ventilation package incorporated:

• ATEX Zone 1 rated extract fan systems
• tempered supply-air ventilation
• inline filtration systems
• galvanised ductwork installations
• fire dampers and ventilation grilles
• intelligent control systems
• integrated pentane gas detection and monitoring

A dedicated gas-detection system featuring high-sensitivity pentane detectors was integrated with the ventilation controls to provide continuous monitoring, automatic safety responses, and audible and visual alarm indication throughout the operational area. The project also included associated electrical installations, controls integration, commissioning, CAD drawing production, operator training and full O&M documentation — delivering a safe, compliant and reliable ventilation solution for the facility.

Utility infrastructure upgrades

To support the operational demands of the new facility, significant upgrades were completed across the site utilities.

Electrical upgrades

We delivered a full electrical infrastructure package as part of the new ICF manufacturing facility. The project included the design, installation and commissioning of a large-scale industrial electrical system to support advanced manufacturing equipment, production machinery, utilities and wider site operations.

A new high-voltage electrical package was delivered to provide the incoming power capacity required for increased production demand and future site expansion. HV installation works included the supply and installation of a 1500 kVA ONAN 11kV / 433V Tier 2 transformer, together with an HV circuit breaker and protection system, providing safe, efficient and reliable power distribution across the facility. A new 2500 A LV distribution cabinet with integrated air circuit breaker protection was also installed to support downstream distribution throughout the manufacturing operation.

The package included equipment delivery, installation, HV / LV cabling, electrical integration and connection works to establish a robust and scalable power network. Installation was designed in line with recognised UK standards and regulations, including BS 7671 (IET Wiring Regulations), BS EN 61936-1 (Power Installations Exceeding 1 kV AC), BS EN 60076 (Power Transformers), BS EN 62271 (HV Switchgear) and the Electricity at Work Regulations 1989, together with applicable DNO connection requirements.

The works also involved the installation of new LV power distribution systems, high-capacity submains, industrial busbar systems and specialist electrical infrastructure designed to meet the demands of a modern, high-output manufacturing environment. New 2000 A and 1600 A LV panels were installed, complete with surge protection, fire suppression, energy monitoring and future provision for power-factor correction.

Extensive power distribution systems were installed throughout the facility to supply key production equipment, including moulding machines, conveyors, stackers, compressors, cooling systems and pre-cut machinery. Additional works included industrial socket installations, maintenance power supplies, containment systems, cable-ladder gantries and specialist wiring infrastructure across all production areas.

The project also included:

• production and mezzanine lighting installations
• ATEX-rated power and lighting systems within the silo area
• fire alarm and intruder alarm integration
• data cabling and communications infrastructure
• CCTV and security systems
• earthing and bonding for 14 silos
• gatehouse and car-park barrier power supplies and controls
• electrical installations for welfare, office, boiler house, compressor room and tool room areas

Specialist ATEX-compliant electrical systems were installed within the hazardous silo environments using certified contractors experienced in controlled industrial areas. Alongside the installation works, the project included detailed electrical design, cable calculations, CAD drawing production, testing, commissioning, certification and system monitoring to ensure full compliance, long-term reliability and future scalability.

Water infrastructure

Water infrastructure across the facility was upgraded to support the increased demands of the new operation, providing reliable supply to production processes, building services and critical fire-protection systems. The scope included the installation, upgrade and commissioning of new water supply infrastructure, together with associated distribution pipework, to deliver the capacity and resilience required for long-term operation. To ensure the system met water-quality requirements, specialist water-main flushing, decontamination and disinfection works were completed prior to commissioning.

All installation and commissioning activities were delivered in accordance with recognised UK water-industry standards and regulations, including the Water Supply (Water Fittings) Regulations 1999, Water UK guidance for mains disinfection and commissioning, the Water Industry Act 1991, and BS EN 805 for the installation and testing of external water supply systems.

The completed works provided the facility with a safe, compliant and dependable water infrastructure network capable of supporting continuous operations and future growth.

Incoming gas supply upgrade

We delivered a new incoming gas infrastructure package to provide the utility capacity required to support expanding manufacturing operations and future site growth. Works included the supply, installation and commissioning of a dedicated gas connection to serve key plant and process equipment across the facility.

The works also included utility coordination, installation of the incoming gas supply, connection and integration with site services, and commissioning activities to ensure safe and dependable operation within a live industrial environment. The installation was designed and delivered in accordance with recognised UK standards and industry requirements, including the Gas Safety (Installation and Use) Regulations 1998, IGEM standards for industrial and commercial gas installations, BS EN 1775, and applicable gas network and building regulation requirements.

The completed works provided a safe, compliant and future-ready gas infrastructure solution, supporting increased production capacity and a strong foundation for continued growth.

Fire suppression system upgrade

A major fire-protection upgrade was delivered to support the changing operational requirements of the manufacturing environment and strengthen overall site resilience. The project involved the removal and replacement of the existing roof sprinkler system, together with upgrades to the associated pump equipment and distribution pipework, creating a modern and reliable fire-suppression solution. Works included the supply, installation, modification and integration of new sprinkler infrastructure across the production areas, incorporating upgraded roof-level coverage, new pipework and associated pumping equipment designed to improve system performance and reliability.

The fire-suppression system was designed and delivered in line with recognised UK and international fire-protection standards, as well as the client’s risk-management insurance specifications, including:

• BS EN 12845 — Automatic sprinkler systems
• NFPA fire-protection requirements referenced within the project specification
• Regulatory Reform (Fire Safety) Order 2005
• UK Building Regulations — Approved Document B (Fire Safety)

The completed works provided a robust, compliant and future-ready fire-protection system — helping to protect people, manufacturing assets and critical production infrastructure while supporting safe, reliable long-term operation.

New plant rooms and welfare facilities

We delivered a complete structural-steel and internal infrastructure package to create the key operational spaces required to support production, utilities, maintenance and day-to-day operations. This included the design, manufacture, supply and installation of bespoke internal structures — a production office mezzanine, silo enclosure, boiler house, compressor room and dedicated maintenance storage platform — developed to improve space utilisation, streamline operational flow and support future growth.

A large mezzanine structure was installed to provide additional office and storage capacity. Constructed using CE-marked structural steel, the installation incorporated galvanised secondary steelwork, high-density flooring systems, integrated stair access and dedicated loading areas. Specialist structural steelwork was also delivered to form enclosed silo, boiler and compressor plant areas, complete with 60-minute fire-rated partition systems and fire-rated access doors to improve safety and operational separation.

All works were designed and delivered in line with recognised UK standards, including BS EN 1993 (Eurocode 3) for structural steel design, BS EN 1090 Execution Class 2 for the fabrication and installation of structural steelwork, and applicable UK Building Regulations covering fire safety, structural performance and access requirements.

Plant utility systems

Steam generation

We delivered a complete steam-generation and process-utility package to support critical manufacturing operations and provide a reliable thermal energy source across the facility. This included the supply, installation and integration of a high-capacity steam boiler system complete with steam accumulator and associated process equipment.
The installation incorporated a high-efficiency three-pass wet-back fire-tube boiler, together with burner systems, feedwater equipment, process controls, instrumentation and safety systems. To improve plant performance and reduce energy consumption, the system also included heat recovery through an economiser. Extensive steam supply and distribution pipework was installed throughout the facility, with works including the fabrication and installation of process pipework, support systems, valves, expansion allowances, testing and commissioning.
To improve energy performance and protect personnel, all steam and condensate pipework was finished with high-performance thermal insulation designed to minimise heat loss and maintain safe surface temperatures. Pipework was fully identified and labelled in accordance with recognised UK standards, incorporating colour coding, flow-direction marking and service identification.
The installation was designed and delivered in accordance with recognised UK standards and industry requirements, including:

• Pressure Equipment (Safety) Regulations 2016
• Pressure Systems Safety Regulations 2000 (PSSR)
• BS EN 12953 — Shell boilers
• BS EN 13480 — Metallic industrial pipework
• BS EN ISO 12241 — Thermal insulation for building equipment and industrial installations
• BS 1710 — Identification of pipework and services
• BS EN 60204-1 — Electrical equipment of industrial machinery

Compressed air generation

We delivered a complete compressed-air and process-utility package to provide a reliable, energy-efficient air supply across the manufacturing operation. The project included the supply, installation and commissioning of a high-capacity compressed-air system incorporating two 110 kW variable-speed screw compressors and two 5,000-litre air receivers to provide stable operating pressure, improved resilience and efficient energy management. A dedicated air-treatment package featuring refrigeration drying, multi-stage filtration, condensate management and system controls was included to maintain air quality and protect downstream equipment.
Extensive compressed-air and process distribution pipework was installed across the facility to serve manufacturing process equipment, the QA laboratory and utilities. Works included the fabrication and installation of distribution pipework, supports, valves, testing, commissioning and full integration. All services were completed with pipework identification and colour coding in accordance with UK standards. The system was designed and delivered in line with recognised UK standards and industry requirements, including:

• Pressure Equipment (Safety) Regulations 2016
• Pressure Systems Safety Regulations 2000 (PSSR)
• BS EN 1012 — Compressors and vacuum pumps: safety requirements
• BS EN 13480 — Metallic industrial pipework
• BS EN ISO 8573 — Compressed air quality
• BS EN ISO 12241 — Thermal insulation for industrial installations
• BS 1710 — Identification and colour coding of pipework services
• BS EN 60204-1 — Electrical equipment of industrial machinery

Production line installation and integration

Following the successful completion of the infrastructure and enabling works, the production equipment and associated systems were installed, commissioned and fully integrated within the facility.
We managed the end-to-end tendering and procurement process, appointing Italian EPS moulding specialists to supply advanced shape-moulding automation equipment and bespoke end-of-line automation. The systems were specifically engineered to align with the client’s operational requirements, production targets and facility space constraints — ensuring efficiency, scalability and long-term performance. This phase included the following.

Silo system

A bespoke, fully automated silo management system comprising 14 fabric silos, manufactured with a heavy-duty galvanised steel structure and providing a combined storage capacity of 166 m³ of pre-expanded EPS at a density of 22 kg/m³.

EPS pre-expansion

A fully automated pre-expansion system, including a raw-material loading hopper, pre-expander, density controller and fluidised drying bed, with product transfer into the silos.

Shape moulding

Fully automated shape-moulding machines, capable of producing 90-degree and straight ICF products to the client’s specification, quality and throughput requirements.

Product handling

A bespoke, fully automated end-of-line handling and packaging solution was designed and integrated to optimise production efficiency, improve reliability and support high-volume output. Engineered to align with the client’s production requirements, product flow and facility layout, it incorporates advanced automation to streamline material handling, product transfer, stacking and final processing. The solution minimises manual intervention, enhances consistency and improves throughput while supporting a safer, more efficient environment. Works included:

• bespoke end-of-line automation equipment
• controls integration
• instrumentation
• electrical connections
• operational testing
• close coordination between installation teams, suppliers and commissioning personnel to prepare the production systems for start-up and operational handover

Safety throughout the project

Planning to deliver World class safety performance was essential.

Contractor selection and coordination, tight design briefs, task supervision and work area allocation, Daily coordination meetings, risk assessments, permit-controlled activities and lift-planning procedures were implemented across all works.

It was essential to us and to all parties working on the project to maintain the very highest standards throughout installation and construction.

The combination of heavy-equipment handling, confined installation areas, utility works and multi-disciplinary activities required careful management and close collaboration between all teams on site.

Project outcome

Following successful delivery, the facility was transformed into a modern, fully integrated production environment designed to support increased manufacturing capacity, long-term operational efficiency and future growth. Through a combination of infrastructure upgrades, specialist installations, utility improvements and production-line integration, the project created a scalable and future-ready manufacturing platform.

Delivered over a 19-month programme, the project coordinated 95+ multidisciplinary international contractors across civil, mechanical, electrical, process and commissioning activities, while achieving zero lost time accidents, injuries and no RIDDOR reportable incidents across 412 working days on site — demonstrating a strong commitment to safety, planning and execution. The completed facility now benefits from integrated production systems, upgraded utilities, improved energy performance and resilient infrastructure built to support continuous operation and future expansion.

This project showcases our ability to deliver complex industrial and manufacturing programmes — combining technical expertise, effective project management and safe delivery to create long-term value for our clients.

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