Perspex International, Darwen
Value - £14.7m | Client - Perspex International & Hart Process Services
Perspex International, a leading UK producer of Perspex® acrylic sheets since 1934, received permission in 2024 for an expansion of its Darwen, Lancashire site, streamlining production and cutting CO₂ emissions and water consumption.
The scheme features a new 1240m² polymerisation building adjacent to the existing facility, and a new tank farm.
The steel framework and structure for the new bath pits.
Appointed at RIBA Stage 2, we delivered civil, structural, geo-technical and MEP engineering. Acting as client agent, we led the tender process, preparing Expressions of Interest, collating tender packages, inviting contractors to tender and reviewing returns to ensure alignment with project requirements.
Our team undertook a tender analysis, negotiating contract costs with the successful contractor, saving the client thousands with key value engineering suggestions incorporated into the contract drawings
The project is under construction, and scheduled for completion in July 2026, following contract award at the end of 2024.
With over 90 years in Darwen, Perspex International’s sole UK site is vital to the town’s industry. The expansion secures its legacy, safeguarding and creating jobs in the local community. The technology the new polymerisation building houses is expected to provide an energy usage reduction of 30000MWh per year, equating to approximately 6000 tonnes of C0₂. In addition to this, water consumption will also be reduced by approximately 100,000 tonnes per year.
The expansion presented significant financial and logistical challenges.
Robust Project Management
We led the tender stage, negotiating the contractor’s price through the introduction of value engineering.
Works were delivered in line with our detailed design drawings. Construction changes were thoroughly checked against the original baseline resulting in minimal changes.
Consequently, the client maintained the budget - an achievement not always seen on similar sized projects.
Innovative Geotechnical Testing
Working with a partner, the team conducted Advanced Continuous Surface Wave (ACSW) geotechnical testing and phase 2 geotechnical investigations to assess ground conditions. This enabled a shift from piled to economical pad foundations, saving around £100,000.
Value Driven Design
Throughout construction, we re-tested the design and made refinements. Variations on the project have been minimal and the client’s budget is on track to be achieved.
Results
The expansion supports local jobs
The polymerisation building technology will cut energy use by 30,000 MWh annually – equivalent to approximately 6,000 tonnes of CO₂
Water consumption is projected to drop by 100,000 tonnes each year
Contact us now if you require multi-disciplinary engineering consultancy.
Services used:
Civil engineering
Structural engineering
Geoenvironmental
Mechanical, electrical, plumbing engineering
Other industrial projects:
