Case Study
IPSEN
Location:
Wrexham, North Wales
Project type:
New-build industrial facility
Project value:
£75 million
Client:
Lovelock Mitchel Architects/ IPSEN
Completion:
2025
Project overview
JPS provided the full structural engineering design for a new £75m pharmaceutical production facility on Wrexham Industrial Estate, working alongside Lovelock Mitchell Architects and IPS Process Engineers. Constructed on a remediated brownfield site, the development required extensive ground improvement works and piled foundations to support a highly specialised manufacturing environment. The scheme incorporated a steel-framed structure with composite concrete floors, long-span storey-height steel trusses, secondary steelwork, reinforced concrete service trenches and ground-bearing slabs. Designed to meet stringent operational requirements, the facility delivers large column-free production areas with integrated plant spaces while maintaining strict performance standards for deflection and vibration control
The engineering challenge
The scheme presented several challenges, including:
- Remediating a brownfield site and implementing suitable ground improvement measures to create a stable platform for construction.
- Designing piled foundations capable of supporting a large-scale pharmaceutical production facility and its associated operational loads.
- Creating extensive column-free production spaces while accommodating significant plant equipment within the building structure.
- Integrating long-span, storey-height steel trusses without compromising structural efficiency or operational requirements.
- Meeting stringent structural performance criteria, particularly in relation to deflection control and vibration performance required for pharmaceutical manufacturing processes.
- Coordinating a complex structural design package across multiple building elements, including steel framing, composite floors, service trenches and foundation systems.
The engineering solution
JPS was responsible for:
- Developing a comprehensive structural design strategy that combined site remediation, ground improvement techniques and piled foundations to address challenging ground conditions.
- Designing a steel-framed structure with composite concrete floors to provide the strength, flexibility and efficiency required for a modern pharmaceutical facility.
- Incorporating long-span, storey-height steel trusses to create large uninterrupted production floors whilst accommodating plant space within the truss depth.
- Undertaking detailed structural analysis to ensure the frame satisfied strict requirements for vibration performance and deflection limits.
- Providing the complete structural engineering design package, including the primary steel frame, secondary steelwork, ground slabs, reinforced concrete service trenches and piled foundations.
- Working collaboratively with Lovelock Mitchell Architects and IPS Process Engineers to coordinate structural solutions with architectural and process engineering requirements throughout the project.
The outcome
- A state-of-the-art pharmaceutical production facility successfully delivered on Wrexham Industrial Estate.
- A structurally efficient building capable of supporting highly specialised manufacturing processes and associated plant equipment.
- Large column-free production areas that maximise operational flexibility and improve manufacturing efficiency.
- A robust foundation and structural system that overcomes the constraints of a remediated brownfield site.
- Compliance with stringent structural performance standards for deflection and vibration, ensuring suitability for pharmaceutical production operations.
