Bruderer Facility

The project presented complex ground conditions and infrastructure needs requiring proactive management to maintain workflow and meet technical requirements. Winter ground conditions from November to February created challenges for drainage and foundation installation, requiring careful scheduling to maintain programme. The site required a special crane mat tested for load-bearing capacity to safely support an 80-ton crane, highlighting strict engineering safety standards. Ground insulation was required around three footings to protect against tree root intrusion, preventing structural damage and ensuring long-term structural stability.

Collaboration with local authorities was critical for timely service connections, complicated by temporary delivery restrictions during road works. Early installation of drainage before cladding represented a deliberate deviation from usual practice, requiring careful sequencing to prevent later delays and ensure welfare facilities were operational early. The installation of the 25-ton external crane and 1-ton internal crane required detailed structural reinforcement and early service integration, with the internal crane needing on-site assembly in parts before being lifted into position, reflecting significant logistical planning for bulky equipment within a finished space. Structural engineer input was essential to design reinforced concrete floors and crane rails capable of supporting crane loads without movement during testing.

The project prioritised energy efficiency through building design and regulatory compliance to reduce operational costs. The site team maintained progress throughout winter ground challenges, ensuring drainage and foundations were installed early to keep on schedule.

The building incorporated insulated cladding and built-up insulated roof to lower energy bills, paired with air conditioning in office spaces as required by planning conditions. Roof-mounted photovoltaic panels were integrated as a strategic choice driven by client planning requirements to further reduce operational energy costs. Frequent visits from building control ensured compliance with insulation, reinforcing and other critical elements, reducing rework risks throughout the programme. Frame erection was completed in an impressive six days by a specialist steel contractor, with a lift shaft integrated mid-erection to accommodate vertical access requiring precise coordination with crane installation.

Structural engineer input designed reinforced concrete floors and crane rails capable of supporting crane loads without movement during testing. Utility services were embedded into the concrete floor before pouring to support ongoing operational requirements.

Collaboration with Telford & Wrekin Council and Severn Trent Water ensured timely service connections despite site access challenges.

The Bruderer UK facility was successfully completed in July 2024 within 37 weeks, slightly over the planned 36 weeks with an extension of time agreed due to client unavailability, reflecting flexible project management.

The project was delivered on time and to budget, allowing Bruderer UK to continue supporting the manufacturing industry whilst successfully relocating from Luton to Telford.

The building passed air testing with a score of 3.7, with insulation and efficient design significantly reducing operational costs. The 25-ton crane installation was completed successfully with reinforced concrete floors and crane rails performing to specification without movement during testing.