New Build Ammonia Plant Room: Large Bakery, Cornwall

Client: Undisclosed

Duration: 5 Months

Location: Cornwall

Year: 2024

Value: Undisclosed

Overview & Objectives

A leading producer of baked goods in the UK, initiated “Project Frosty” to support its expansion and energy saving goals. This project involves the construction of a ammonia plant room to house critical equipment and machinery. Ambrey Baker Construction was selected to manage the design, fabrication, and construction phases.

Scope of Work

• Design & Fabrication: Ambrey Baker is responsible for the complete design, fabrication, and construction of a 16m x 16m plant room. The structure will be built using PIR composite wall panels and a Kingspan top deck roof system, ensuring durability and compliance with fire safety standards.
• Pipe Bridge Installation: A key aspect of the project is the construction of a pipe bridge to connect the new plant room to the main factory. A provisional sum has been allocated to ensure this connection is made seamlessly, supporting the integration of the new facility with existing operations.

• Regulatory Compliance: The project falls under CDM Regulations, with Ambrey Baker serving as both CDM Principal Contractor and Designer. This includes setting up a site compound adjacent to the construction area to facilitate smooth and efficient project execution.
• Functional & Aesthetic Integration: The plant room’s walls will be colour-matched to blend with the existing factory, and the structure will include high-level louvres for ventilation and a CAT ladder roof access system.

Challenges & Solutions

Challenge: Building a large plant room within an active bakery without disrupting operations.
Solution: Phased construction with a dedicated site compound for efficient access and
storage.

Challenge: Navigating CDM Regulations while managing safety and design standards.
Solution: Implemented regular safety audits and maintained strict compliance through detailed
planning and collaboration.

Challenge: Seamlessly connecting the new plant room to the existing factory
Solution: Advanced modeling and strategic

Outcomes

Minimal Disruption: The phased construction approach has allowed the bakery to continue operations smoothly without major interruptions.
Enhanced Capacity: Once completed, the new plant room will significantly increase production capacity, supporting The Cornwall Bakery’s growth Seamless Integration: The new
infrastructure will integrate smoothly with the existing facility, ensuring efficient operations with minimal
maintenance needs.