Celotex Eggborough Composite Panel Factory

Overview

Saint Gobain commissioned Mason Clark Associates (MCA) to lead both the design and construction of a state-of-the-art facility for the production of insulated building panels.

Following a competitive tender process, MCA was selected to act as Design Team Leader and Lead Consultant, demonstrating both cost-efficiency and high-quality expertise.

The facility represents a large investment in building solutions that are sustainable and aims to support the future of energy-efficient construction.

Challenges and Solutions

This project presented a unique set of challenges that required creative problem-solving and close collaboration with all stakeholders:

• Planning and environmental concerns: although the site was located on a brownfield, planning authorities raised issues regarding potential carbon emissions and the building’s impact on the local ecology due to its height and design. To mitigate these concerns, We worked closely with local planners, establishing a Planning Performance Agreement (PPA) to fast-track the approval process. Regular consultations ensured that we were in compliance with planning requirements and that the project could proceed without delays.

• Unanticipated underground infrastructure: during early stages, a Yorkshire Water main, unmarked on any statutory documents, was discovered running directly through the site. This unexpected obstacle had the potential to cause significant delays. To address this, we quickly developed an alternative plan to divert the water main while allowing construction to continue on either side of it. Our proactive approach ensured the project remained on schedule despite this challenge.

MCA's Contribution

As Design Team Leader and Lead Consultant, we were responsible for coordinating the efforts of architects, civil and structural engineers, mechanical and electrical engineers, and cost consultants. By conducting regular design team meetings, we were able to identify and manage risks early, ensuring that both timeframes and budgets were maintained.

Our services included:

• Developing an efficient, fast-tracked design process to meet the tight schedule
• Managing all aspects of planning, from statutory surveys to environmental compliance
• Handling unforeseen obstacles, such as the water main, with minimal disruption to the overall project timeline
• Ensuring that the client remained closely involved through regular updates and consultations with the entire design team

Results

Despite the unforeseen challenges, the Celotex Eggborough factory was delivered on time and within budget. By absorbing costs related to the water main diversion into other areas of the project, we ensured there was no financial impact on the client. The project has been a resounding success, and our experience has reinforced the importance of thorough site investigations in future developments.

Through careful planning, expert management, and a commitment to client collaboration, we have successfully delivered a cutting-edge facility that will contribute to the future of sustainable construction.