Pharmaceutical Salt Manufacturing Facility | TATA Chemicals/British Salt, Middlewich
Following completion of a detailed design phase, ACS has successfully delivered a £5 million civils contract to construct a new manufacturing facility for a global pharmaceutical business.
Challenge.
Civils and structural works
ACS Construction Group was responsible for comprehensive civil works that encompassed:
- Earthworks and piling: site preparation included extensive earthworks and foundation piling to support the facility’s structure.
- Concrete slab construction: multiple reinforced ground bearing concrete slabs.
- Drainage and hardstanding: installation of a drainage system along with hardstanding for site durability and usability.
- Landscaping: final landscaping around the facility to enhance the site’s appearance and functionality.
Building erection
ACS oversaw the erection of a substantial 30-meter-high steel frame building. Key elements included:
- Steel frame construction: built with steel cladding and composite roofing to ensure durability in the high-salt environment.
- Composite cladding system: TATA trisomet system include fall restraint system to the roof.
- Composite concrete floors: constructed across four levels to provide stable, multi-level workspaces.
- Access points: installed personnel doors and roller shutter doors at various levels of the building.
Solution.
Ground conditions – hazardous material management
During excavation, ACS encountered “puri,” a hazardous byproduct of historical salt production, at 1 meter below ground level. Removing this material offsite would have incurred significant costs. To mitigate this, ACS collaborated with the client’s designers to develop a Material Management Plan (MMP), allowing for safe segregation and reuse of puri material as backfill in appropriate areas, reducing both cost and schedule risks.
Atmospheric corrosion – steel protection
Due to the high-salinity atmosphere (classified as a “C5 Environment”), steel structures on-site required enhanced protection against corrosion. ACS implemented a strict Inspection and Test Plan (ITP) to ensure that the steel protection system was correctly applied at every stage. This adherence to the ITP assured compliance with quality standards and minimised potential for structural degradation.
Silo installation coordination
ACS coordinated with Titan Salt, a specialist from the Netherlands, for the concurrent installation of large salt silos. Each silo, measuring 3.5m wide, 11m long, and weighing 3.4 tonnes, required lifting 30 meters high into precise positions. ACS procured a 100-tonne crane to manage these lifts, ensuring safe and efficient installation with minimal disruption to ongoing construction.
Outcome.
The Middlewich project was completed successfully, with a focus on proactive risk management, strict adherence to quality processes like ITP, and effective collaboration with third-party partners. ACS’s approach contributed to a high-quality, durable salt manufacturing facility and reinforced a strong partnership with British Salt.
