Shot Blast Chamber

Engineering Company

Background

Stancold were approached by a leading abrasive blasting supplier to design and install a shot blast room suitable for surface blasting mechanical equipment.

Requirement

To deliver and install insulated panels forming an 8.08m x 4.66m x 4.58m high booth with self-supporting ceiling mounted to a steel frame.

Solution

Following a detailed evaluation and taking into account the application, Stancold have created a well-sealed environment using 80mm PIR panels, which combine sturdiness with good acoustic performance containing noise levels associated with shot blasting.

The project was completed within 4 days to the client’s full satisfaction.

10 out of 10 across the board. We are very happy with your services.

Purchasing Manager, Abrasive Blasting Supplier

PIR insulated panels for shot blast chamber

Location	Llantrisant, Wales
Description	Shot Blast Chamber
Building Use	Precision Component Manufacture
Panel Type	PIR Panel
Thickness	80mm
Ceiling	Self Supporting Ceiling
Dimensions	8.08m x 4.66m x 4.58m High
Doors	Personal Access Door Option Available

FM-approved Cleanroom Upgrade

Electronic Components Manufacturer

Background

Our client, a global manufacturer of electronic components for the automotive sector, contacted CREST with a need to upgrade their existing cleanroom facility on site in Bedford.

They sought after an architectural envelope contractor that could supply and install an FM-approved cleanroom system in order to comply with their latest insurance conditions.

Process

Following a site visit to understand the scope of the project in more detail, CREST proposed to undertake the removal of existing cleanroom walls followed by their replacement with the FM Approved Puracore system, including all doors and vision panels.

Given our client’s operational commitments, a 10-day shutdown of the main cleanroom was agreed, but most of the works on site had to be completed while it was still operational.

Project Delivery

Working within a live cleanroom environment required a stringent construction schedule and daily health & safety briefings to manage personnel moving in and around the works area.

This also meant that some areas of the existing cleanroom envelope couldn’t be assessed while the original site surveys were carried out, so CREST’s site and in-house design teams worked in real time to identify issues and update drawings.

The flexibility of Puracore’s cleanroom system combined with CREST’s experienced workforce allowed for on-site adaptations easily, which saw the build handed over within 12 weeks.

A real pleasure to assist our client with this cleanroom upgrade

Lee Duffield, CREST Construction Director

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Non-Fire-Rated Enclosure

Advanced Manufacturer

Background

An advanced manufacturing company from Dorset reached out to Stancold, looking to enclose a space in their old warehouse and make it fit their current standards.

Process

We took on a turnkey contract to deliver the 364 m² box. Due to the building’s limitations, part of the scope included putting in place the steelworks to support the panels.

Stancold engaged a third-party supplier to design a purposefully-built steel frame. Rather than placing panels adjacent to existing columns, we commissioned and oversaw the design & build of a fit-for-purpose solution to form a self-standing structure, liaising with the subcontractor on value-engineering their works to our requirements.

Project Delivery

The client’s strict production schedule meant our team had to adapt the installation process, necessitating a phased delivery with multiple visits. This required the space to be partially usable before completion, demonstrating the flexibility and modularity of composite-panel-system-based builds.

Great work from the team proving we can successfully deliver a project outside of our comfort zone

Sam Glover, Stancold Project Service Manager

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Turnkey Pharmaceutical Cold Stores

Overbury

Background

CREST were approached by leading fit-out company, Overbury, as a specialist pharma cold storage contractor for one of the world’s leading biopharmaceutical innovators.

A pharmaceutical cold room was required on each floor of the end user’s two-storey research & development site in Stevenage, and came as part of wider ongoing refurbishment and modernisation works.

Process

CREST’s expertise in turnkey cold store construction for high-value pharmaceutical products confirmed that we were able to provide vital N+1 redundancy solutions and select a sustainable refrigerant option in line with the project specification.

Our team worked closely with Overbury during negotiations to ensure that the specification and build programme were in line with the end user’s requirements.

Project Delivery

Both turnkey cold room packages were designed and built to maintain an internal temperature requirement of +4°C. The rooms themselves utilised a panel system with FR30 rating, as per the contract’s specification.

Working on the first and second floor of the building meant materials were maneouvred via an internal freight lift and external hoist, a challenge that the team are well-versed in navigating from previous site experience.

Aligning our start on site with a rescheduled programme of works required pro-active coordination to ensure that the project was completed in a timely manner and to the end user’s satisfaction.

A successful turnkey contract for high-value pharma products

Steve Gunning, CREST Contracts Supervisor

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Biomedical Holding Freezers

Pharmaceutical Manufacturer

Background

CREST previously completed the envelope fit-out of six cleanroom suites on this pharmaceutical manufacturing site and thanks to unrivalled knowledge of turnkey cold storage construction within the industry, were subsequently appointed for this requirement too.

Process

Situated in a modular warehouse on the ground floor of the site, our client required two industrial freezers for additional product storage. The specification required product to enter the room at -20°C and be maintained at this temperature.

CREST undertook the turnkey package, which included refrigeration, lighting, shelving and access ramps.

Project Delivery

CREST successfully coordinated the room build, commissioning of refrigeration and installation of internal shelving in line with our client’s specification.

The scope also included removable access ramps, person trapped alarms and door release functions, with racking designed around evaporators to optimise airflow.

Utilising knowledge of the different elements required for a turnkey solution like this ensured a seamless programme of works through CREST as the appointed contractor.

CREST has unrivalled expertise in turnkey pharma cold storage

Steve Gunning, CREST Contracts Supervisor

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Fire-Rated Cleanrooms

Rydon Construction

Background

Following previous experience with the contractor, CREST were invited to tender with Rydon Construction for the fire-rated cleanroom fit-out of a new purpose-built aerospace centre in Bristol.

Process

Our team were involved from the early stages of this project to assist with the technical specification that included both passive fire protection and ISO standard cleanrooms.

Negotiations and design meetings were conducted virtually due to COVID-19, before site surveys followed once the green light was given for the project.

Project Delivery

CREST installed composite walls, ceilings, doors and vision panels to form a number of areas as part of the fit-out. This included production and preparation zones and accompanying airlocks.

The project utilised Eurobond’s Firemaster system with a white food-safe coating throughout, which achieved both a FR30 rating and a cleanroom finish to meet the specification requirements. System doors were also included to ensure no necessary additional secondary steelwork was needed.

Working alongside other contractors within an open warehouse required methodical planning and co-ordination by the team and was managed well to ensure that our build schedule was uncompromised.

You managed issues with delay (by others) well

Neil Spurway, Rydon Construction

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Fire-rated cleanrooms for aerospace Bristol

FR30 and cleanroom finish across the facility

Sub-Dividing Firewall For New Warehouse Tenants

Choose Design Ltd

Background

Stancold were extremely pleased to be approached by maritime repair services provider, Choose Design, who were looking to sub-divide their warehouse space in Southampton. Where temporary walls previously existed, passive fire protection was now a key requirement.

Process

Following the submittal of initial budget costs, our industrial partitioning expert, Shaun Jones, completed a detailed site survey. This allowed him to develop a value-engineered solution that utilised existing steelwork on site, as well as both vertical and horizontal installation methods to reduce costs for the client.

Project Delivery

Our LPS-approved installation team began their two week-long installation process within 6 weeks of initial contact with the client. We used the perfectly-suited Eurobond Firemaster panel system to achieve the 60-minute fire-rating specified for the firewalls. In order to make most efficient use of the space, a dog-leg design was implemented. Furthermore, allowing the client to sub-divide a certain area of their space more specifically than what would be possible with an individual partition.

Choose Design are soon welcoming new tenants into the sub-divided space, where it will be used for automotive detailing and other related services. Our team worked effectively across the live site to ensure a very quick turnaround on the project as a whole.

The team worked well to minimise disruption on a live site

Sarah Gore-Booth, Project Coordinator

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Temperature-Controlled Biopharmaceutical Production Facilities

Area

Background

Commercial workplace specialists, Area, part of the wider Fourfront Group, required a contractor to undertake the design and build of four temperature-controlled facilities within a newly built warehouse in Hampshire.

The warehouse’s new tenant manufactures key machinery systems for the life sciences and biopharmaceutical sectors, and this area will house the final testing phase of their production line.

Process

CREST worked closely with Area’s team and our recommended refrigeration partner to find a system that would accommodate the required temperature range of +2°C to +26°C.

Where the facility operates a large robotic crane, CREST also carefully considered different door options and proposed a suitable solution as part of our package.

Project Delivery

CREST delivered four chilled rooms and accompanying doors to facilitate this project’s specification. Kingspan’s Quadcore panel system was the best suited option for this application, thanks to its reliable insulating properties, and space-saving roller-shutter doors integrated within the design to accommodate the warehouse’s crane.

Two areas were built beneath an 8m-high mezzanine floor, so the team created an efficient workaround plan to install ceilings safely, where access was particularly tight. Manoeuvrability of wall panels and use of lifting equipment in this space were also carefully monitored, especially when coupled with other craning machinery within the main warehouse.

CREST successfully completed the works within 3 weeks, demonstrating strong expertise and faultless construction technique for this application.

Our team successfully achieved the intricate specification

Sam Glover, Senior Contracts Manager

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ISO 8 Cleanroom for Electrical Components Manufacturing, Dundee

Electrical Manufacturing

Background

Stancold worked with cleanroom contractor, Monmouth Scientific, in Dundee to successfully construct a new cleanroom for an electrical components manufacturer.

Process

Stancold’s strong expertise in the design and build of the cleanroom envelope were fully utilised throughout this project, where three different panel systems were integrated to create a new ISO 8 cleanroom and glazed office partitioning.

Our team were able to offer valuable advice on each system and discuss how it would work within the finished facility, all confirmed with a site survey to visualise the agreed design and understand site conditions.

Solution

The project encompasses approximately 523m² of insulated panelling, with the ISO 8 cleanroom constructed using the semi-flush Kingspan Versatile system, of 100mm thickness.

The accompanying office space utilises a Puracore glazed wall system, which includes 50mm Aluminium Honeycomb panels with frosted double-glazed flush windows and a fully glazed door. All ceilings across the two areas employ the Kingspan Versatile system. Mineral Fibre panelling was also installed as part of this project’s specification.

Our installation team’s panel construction expertise was fully exercised throughout, as the build was carried out while the facility remained operational, thus not impacting on the end user’s production capabilities.

Utilising three panel systems demonstrated the team's excellent construction experience

Lee Duffield, Project Manager

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Inside the ISO 8 cleanroom for electrical component manufacture

Cleanroom for electrical component manufacture

ISO 8 & 9 Cleanroom Areas for Aerostructures Manufacturing, Scotland

Aerostructures Manufacturing

Background

Working with Specific Environments, our end user required ISO standard 8 and 9 areas as part of a new aerostructures research and development complex within a large hangar in West Scotland.

Process

A site survey determined all design and construction details for the project, allowing our CAD team to expertly create accurate drawings, gaining approval from the client and preparing the Stancold team for the build.

Co-ordination of materials, plant and ancillaries was a key factor of the planning process, given its rural Scottish location and 400-mile distance from Stancold’s Head Office.

Solution

Stancold completed the install using Kingspan Versatile Quadcore panels, a composite system designed for semi-flush cleanroom environments such as this.

The team were responsible for all 50mm and 80mm hygienic panelling, spanning over 1500m², and the 100mm walk-on ceiling, to be used for maintenance access. Rapid-rise doors, personnel doors and single-glazed vision panels completed the build.

The team worked really hard to construct within and around the existing steelwork on site, alongside other contractors, to complete the project to our client’s programme of works.

A successful cleanroom build for an exciting project

Lee Duffield, Stancold Project Manager

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Low Humidity Cleanroom For Battery Production, Romsey

Battery Technology

Background

Stancold recently travelled to Romsey to install a fully flush cleanroom system for a specialist in solid-state battery production.

Process

Our extensive knowledge of different cleanroom systems on the market allowed us to suggest what would be best suited to this project and then adapt based on the user’s specific requirements.

Once confirmed, our projects team commenced with site surveys, construction drawings and door schedules in preparation for the start date.

Solution

Stancold utilised the Kingspan Precision cleanroom system; a framed, flush system where panels were made to size, alongside the expert installation of flush vision panels, a full-height glazed wall and flush hinged personnel doors.

Chiller doors were also selected and integrated into the build of the main cleanroom areas, as they demonstrated the most appropriate sealing properties to establish a very low humidity level that is required when working with lithium.

Being able to adequately meet the various requirements of this project, from humidity levels to a fully flush system, was due to the team’s experience and knowledge in working with market-leading materials, therefore creating a bespoke facility that met our client’s needs.

Our superior knowledge of the cleanroom market was valuable

Lee Duffield, Project Manager

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Cleanroom Suite & Firewall Partitions for Aeronautical Research & Development

Precision Manufacturer

Background

Using our unique experience of cleanroom design and construction and fire-rated enclosures, Stancold were awarded the project after winning a competitive tender through Principle Contractor, Merit Holdings.

Process

The suite of new cleanrooms was built to grade D classification and the fire-rated enclosures were designed to be clean not classified.

Solution

We installed 6m high freestanding walls with integrated flush cleanroom windows connected to an aluminium T-Bar suspended ceiling grid which formed the plenum and low-level return air cooling coils. The return air ducts were formed using 50mm FM approved Puracore cleanroom walls to a height of 6m and we also provided temperature controlled cleanrooms with Eurobond panels to a height of 8m.

This project showcases our cleanroom expertise

Paul Towse, Project Manager

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Puracore honeycomb panels for aeronautical research cleanroom

Aeronautical cleanroom facility installed by Stancold

Cleanroom installation including flush cleanroom windows

Cleanroom panels in viewing gallery for aeronautical research

ISO 6 Cleanroom for Precision Engineering Manufacturer

Specialist Manufacturer

Background

With their business expanding, this manufacturer was looking to build a new multi-room cleanroom. Our technical expertise means we partner regularly with Monmouth Scientific on cleanroom projects.

Approach

This project required a cleanroom environment for a precision engineering manufacturer. We offered a cost-effective solution that ensured all requirements for a controlled environment were met.

Solution

The cleanroom measures 18.00m x 4.35m x 2.825m high and is split into 4 different rooms. There are 14 (1220mm x 610mm) ceiling openings for HEPA filters and 8 vision panels. The main compartment is ISO 6 standard.

To ensure that the air in this space meets those specifications, Stancold installed two airlock rooms that are controlled with maglock door system.

Another high spec cleanroom that meets ISO6 Standards

Lee Duffield, Stancold

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Installing a multi-room cleanroom for a precision engineering manufacturer

Cutting panels for a cleanroom installation

Cleanroom ceiling with openings for HVAC filter system

One Hour Fire-Rated Hygienic Room for Food Technology Business

Taste Tech

Background

Having previously worked with Taste Tech Limited on a confectionery laboratory, we were delighted to be working with them again on their new hygienic bakery.

Requirement

As a research and development company, Taste Tech needed a bakery in which to test a range of performance-enhancing solutions. The food-safe panel finish enables them to keep the environment hygienic. Flour is highly explosive so Taste Tech also required a 1-hour fire rating for the panels and air ventilation systems.

Solution

A 1-hour fire rated hygienic room measuring 5.00m x 8.00m x 2.70m high using Eurobond mineral fibre cored panel with a food-safe polyester finish. Two fire-rated hinged personnel doors and a vision panel. Two in-tumescent air transfer vents.

We completed the project on schedule and will be working with the client on a new project shortly.

We were very happy with the work you did for us, in fact we have already recommended your services!

Peter Sargent, Taste Tech Ltd

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Completed installation of fire rated bakery unit in Bristol

Completed fire rated bakery on site under mezzanine floor

ISO 7 Cleanroom

Monmouth Scientific

Background

Our client was contacted by a leading manufacturer of conductor and fibre optic cables for the aerospace and defence industries who had the requirement for a new ISO 7 cleanroom.

Process

A 90m² footprint self-supporting cleanroom, complete with an airlock compartment, was required. Our client also required the design to perform with multiple ceiling openings to accommodate the lighting and HEPA filters, all built to a tight deadline and in a working laboratory environment.

Solution

Stancold provided Kingspan insulated wall and ceiling panels, expertly fitted with doors and windows and designed to take the ceiling loads. The project required close project management due to the restrictive programme and site conditions; access was tight and limited. Our experienced team once again rose to the challenge leading to another satisfied client.

Watch the project’s timelapse video here.

Excellent, a job really well done.

Dave Court, Monmouth Scientific

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ISO 7 cleanroom with insulated wall and ceiling panels

ISO 7 cleanroom with insulated wall panels

Car Manufacturing Area

A&H Construction

Background

West Midlands-based building and civil engineering contractors, A&H Construction appointed Stancold for the internal fit-out of a new car manufacturing facility in Banbury, Oxfordshire. The end client is Prodrive, a British motorsport and engineering company specialising in the design and build of race cars and road cars for teams such as Aston Martin, Mini and Subaru.

Process

Supply and installation of internal firewall partitions and compartmentalisation over 3 floors, building dwarf walls to create work areas and office cubicles.

Project Delivery

Stancold were involved in the early stages of the construction works, overseeing the logistics of panel deliveries and making sure the project ran smoothly despite difficult site conditions. Some of the walls were up to 14m high so extra precautions have been taken to lift the panels and install them safely at height.

Design and installation went very well.
I'll rate you 9 out of 10

Brett Cartright, A&H Construction

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firewall partitioning in car manufacturing plant

firewall partitioning for car manufacturing area

Research Laboratories

Johnson Matthey

Background

Johnson Matthey are a leading international chemicals and precious metals company headquartered in London.

Requirement

Stancold were contracted to build 2 research laboratories the area of 72m² and 36m², ladder enclosure and suspended ceiling in a high security environment.

Solution

In the absence of a structural beam, Stancold have created a specialist galvanised angle to suspend the ceiling from. The walk-on ceiling has provided the customer with easy access to their pipework ring main, thus reducing potential downtime in production areas. The ladder enclosure has provided excellent dust control which is of particular importance due to the product inspection requirements.

I will certainly recommend you and your installation team.

Mark Wall, Johnson Matthey

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Data Stores

EPI

Company

EPI is an international provider of power protection and data centre solutions.

For over 20 years, EPI has been designing, building, upgrading, maintaining and protecting the physical network infrastructure of some of the world’s largest companies.