Case Study


Tarmac Building Products


Linford, Essex


De-mothballing Project




Tarmac’s Building Products Division boosted the manufacturing capacity of their aerated blocks by re-opening the second of its two existing factories at Linford, Essex. The factory was extensively upgraded, building upon Tarmac’s existing nationwide blocks supply capabilities.

The Project Scope

PROjEN were engaged to work as part of an integrated execution team which included the client and key technology providers. The project was driven to a tight deadline in order to realise the requirement to double the sites product capacity before the end of 2017.

Key activities which were carried out included:-

  • Project Management
  • Construction Management
  • Principal Contractor (CDM 2015)
  • Cost Management
  • Procurement Services.

Other key tasks which were pertinent to the successful delivery of this project included; managing Site Safety, the implementation of a new steam generation boiler plant and an overhaul of the autoclaves, including a new steam piping system and new cladding.

The Challenge

This project involved the reinstatement of a production building that has remained unused since 2008. When it was closed down, very little was done in terms of decommissioning or mothballing the facility, and since then the unit has been scavenged for parts to support other operational units on site. Hence the project required a significant amount of upfront survey work and patience to establish and safely control the removal, repair and reinstatement of production units and associated ancillary systems.

Control Systems and legislative requirements (particularly DSEAR and Functional Safety), had progressed since 2008 which has necessitated the re-specification and redesign of a significant proportion of the control and instrumentation infrastructure. The Civil and Structural elements of the facility were also neglected and are subject to a number of repair / improvement activities.


This project was successfully delivered on time and within budget.

Project Cost



12 months


Tarmac Building Products


  • Access to a single business with both biogas and natural gas experience was highly desirable but relatively rare in the UK. As PROjEN can boast this combination of skills, the client was able to place a larger element of the scope with a single business thus reducing the number of interfaces/relationships that they had to manage.


Given our wide range of experience in the Bioenergy sector, combined with many years of gas engineering experience, we were the ideal choice and a safe pair of hands for the delivery of this project.