Pharmaceutical Salt Manufacturing Facility | TATA Chemicals/British Salt, Middlewich
The Challenge.
ACS Construction Group was appointed to deliver the full civil and structural works for a new pharmaceutical-grade salt manufacturing facility at British Salt’s Middlewich site.
The facility plays a key role in supplying global pharmaceutical markets and required a robust, high-specification build capable of withstanding challenging ground conditions and a high-salinity environment.
The Solution
Working from a completed design phase, ACS delivered the project through carefully managed civil, structural, and environmental engineering practices, coordinating with international suppliers and adhering to rigorous quality standards.
Civil Engineering & Groundworks
- Earthworks & Piling: Extensive excavation and foundation piling to support the 30m-high structure
- Landscaping: Final landscape works completed to enhance site functionality and visual impact
- Reinforced Slabs: Multiple ground-bearing slabs constructed to support manufacturing operations
- Drainage & Hardstanding: Full drainage system and hardstanding installed for durability and long-term usability
The Solution (Continued).
Building Construction
- Steel Frame Erection: 30m-high structure with composite steel cladding and roofing using the TATA Trisomet system, incorporating a fall restraint system
- Composite Concrete Floors: Constructed across four levels to create stable, functional workspaces
- Access Installation: Personnel and roller shutter doors installed at various elevations for operational access
Innovative Problem Solving
1. Hazardous Ground Conditions – ‘Puri’ Management
During excavation, ACS encountered ‘puri’, a hazardous byproduct of historic salt production. Rather than incur high disposal costs, ACS collaborated with designers to develop a Material Management Plan (MMP). This enabled safe segregation and reuse of puri as backfill in controlled zones, significantly reducing environmental impact, cost, and delays.
2. Corrosion Protection – C5 Environment Compliance
Given the high-salinity environment (C5 classification), steel components required robust corrosion resistance. ACS implemented a strict Inspection and Test Plan (ITP) to ensure that protective coatings were applied and inspected at every stage, guaranteeing long-term structural durability.
3. Silo Installation Coordination
ACS worked closely with Dutch specialists Titan Salt to coordinate the installation of oversized silos. Each silo (3.5m wide, 11m long, 3.4 tonnes) was lifted 30m into place using a 100-tonne crane, managed precisely to avoid disruption to concurrent works on-site.
The Result.
The project was delivered on time, within budget, and to the highest standards of safety and quality.
Through proactive risk mitigation, meticulous planning, and close collaboration with international partners, ACS successfully delivered a high-performance, future-ready pharmaceutical salt facility.
