Client: Jaguar Land Rover
Main Contractor: Steel Construction Ltd
Roofing and Cladding Contractor: IRC Carocelle
Building Systems UK: Trisomet® insulated wall and roof panels manufactured in Colorcoat HPS200 Ultra® pre-finished steel in ‘Goosewing Grey’.
Year: 2013

With future proofing in mind, Jaguar Land Rover, the UK’s leading manufacturer of premium vehicles has undertaken a multi-million pound investment in a new state-of-the-art press line at its Halewood operations near Liverpool.

As part of this investment work, which will improve efficiency, speed, quality and safety within the press shop, Jaguar Land Rover needed to extend its car manufacturing operations at the site in order to house a new stamping machine. Installing this new machinery required major reconfiguration of the Halewood press shop.

A steel-framed vertical section was added to the existing building.  The press shop bay extension, which measures approximately 120m x 28m, has increased the footprint of the facility by almost 50% as well as adding an extra 12m of headroom to accommodate the new machinery.

The challenge

Jaguar Land Rover’s Halewood facility is one of the most flexible, advanced automotive manufacturing facilities in Europe, producing high quality Jaguar Land Rover vehicles for over 170 countries.

The press shop works 24 hours a day, seven days a week and feeds body shops across Jaguar Land Rover’s network of plants. In light of this, key factors for this project, in terms of product selection, were the restricted access and complexity of the build, which had to be completed in and around a ‘live’ manufacturing plant.

“Working in and around an operational plant with restricted space meant that the co-ordination of deliveries between all of the on-site trades was vital,” says Steel Construction Ltd Contracts Director Kieron Byrne.

 “We also needed high quality building products that offered ease and speed of installation, and with very precise lead times to ensure the components arrived on-site on time to keep the project on schedule.”

The solution

A fast, consistent and efficient cladding installation was a top priority for the press shop and the system specified was Trisomet® insulated roof and wall panels, manufactured using Colorcoat HPS200 Ultra® in Goosewing Grey for the external side and standard White liner for the internal face.

The cladding was installed by IRC Carocelle who constructed the extension’s envelope using Building Systems UK (A Tata Steel Enterprise)’s high-quality Trisomet® 60mm insulated panels for the wall and Trisomet® 80mm insulated panels for the roof.

These one-fix pre-fabricated construction components have been developed to offer fast and consistent installation and performance. Made to measure, they are designed to reduce the need for further processing on-site.

These high quality lightweight insulated panels are ideal for a number of applications, but are particularly suitable for projects where speed and confined working space are key factors.

“One of the main reasons for specifying Building Systems UK’s insulated panels was their ease of installation on-site. The Trisomet® panels were made to order which enabled a much faster cladding installation, reduced on-site materials handling and less on-site waste”, says IRC Carocelle Managing Director Steve Holder.

The wall panel, with its improved span characteristics, helped reduce the amount of steelwork required, softening the impact on the building’s carbon footprint. Our standard pre-finished steel liner in White also provided a brighter internal environment for employees to work in, as well as reducing lighting costs.

“The site restrictions associated with a working facility, coupled with a fast-track contract timescale, dictated the requirement for a robust, quality product guaranteeing un-hindered site productivity,” adds Mr Holder.

“Working closely with Building Systems UK we were able to stagger the delivery schedule ensuring any disruptions to the daily operational requirements of the client were kept to an absolute minimum. Our delivery performance and responsiveness underlines our ability to support large-scale projects of any size,” said John Clark, UK Business Development Manager at Building Systems UK.

Building Systems UK’s Trisomet® insulated roof and wall panel system installed at the Halewood press shop played a key part in providing Jaguar Land Rover with a highly insulated, weathertight facility that will see them continue to produce Jaguar Land Rover vehicles for many years.