Shanco was appointed to deliver specialist reinforced concrete works for Naylor Group’s new £2m automated manufacturing facility in Barnsley. The £300k package involved casting 85m concrete extrusion bays, forming concrete channels for plant rails, and installing a waste disposal system within a live factory environment. The works supported the commissioning of new lintel extrusion plant machinery while maintaining safe operations on site.
The Project
Shanco was responsible for casting 85m long plinth beds ahead of the main commissioning of the lintel extrusion plant. The scope also included alterations to the existing service slab to accommodate new equipment slabs and a waste disposal system. As part of the upgrade, Shanco installed a two-metre deep pre-cast concrete holding tank on a cast in-situ reinforced concrete slab, alongside concrete channels for a series of rails used to support the extrusion process.
The Challenge
Delivering heavy civils and concrete works inside a live manufacturing environment demanded close control of safety, sequencing and access. The work area for the holding tank installation was constrained, and the excavation had to be supported using temporary sheet piles and frame shoring. The temporary works also had to allow the pre-cast concrete tank panels to be lowered into place safely. Across the project, the team also needed to cast numerous bespoke steel fabrications into the concrete so the extrusion plant could be mounted, aligned and operated to the required standard.
The Approach
Shanco planned the works around the operational demands of the factory, combining reinforced concrete expertise with careful temporary works coordination. The team installed the cast in-situ slab for the holding tank, configured the shoring system to suit the restricted footprint, and created the concrete channels required for the plant rail system and external concrete bed. By coordinating each element of the concrete package with the needs of the new production line, Shanco helped prepare the facility for the next phase of machinery installation and commissioning.
The Results
The completed works gave Naylor Group the reinforced concrete infrastructure needed for its new automated manufacturing facility, including extrusion bays, plant support elements and an integrated waste disposal system. For facilities management teams, the project shows Shanco’s ability to deliver specialist civils, drainage-related infrastructure and reinforced concrete works within live operational sites, where safety, access and programme control matter as much as the build itself.
