BES has completed a modular Quality Control (QC) laboratory in southwest England for a global leader in over-the-counter health and wellness products.
Modular approach to lab design
Delivered on a tightly constrained footprint within a live operational site, the 1,100 sqm single-storey facility was constructed using 29 prefabricated modular units, enabling rapid, efficient delivery with minimal disruption. The building houses high-specification laboratory spaces, including temperature-controlled stability chambers, designed to meet rigorous compliance and performance standards.
BES acted as both principal designer and principal contractor, providing structural, architectural, mechanical, and electrical design services. This integrated delivery approach enabled close coordination across disciplines and ensured that quality and compliance were maintained throughout.
A just-in-time (JIT) delivery strategy
Despite the logistical challenges of the site being adjacent to the client’s main delivery route and lacking a laydown area, BES effectively executed a just-in-time (JIT) delivery strategy. The team collaborated closely with the client to ensure seamless operations throughout the project. This achievement underscores BES’s expertise in managing modular laboratory projects in busy environments.
A key challenge
A key technical challenge was the requirement to provide vibration-free conditions for highly sensitive laboratory equipment within a modular construction format. BES developed a bespoke engineering solution involving nine isolated concrete pads, each structurally detached from the modular frame, effectively eliminating vibration transfer and safeguarding equipment performance.
Through early site investigation work, the team discovered a challenge with the planned drainage design. A gas main was found in an unexpected location, which required rethinking the original design. Working with expert consultants, a solution was found by building a shallow channel on a nearby strip of land to manage surface water effectively. This swale not only solved the drainage issue but also supports the local environment by promoting natural water filtration and reducing runoff.
Health and safety performance on the project was excellent. With over 25,000 hours worked, there were no RIDDOR-reportable incidents and no lost-time injuries, highlighting BES’s proactive and safety-first approach to site management.
Sustainability
Sustainability was a key focus throughout the project. The use of prefabricated modular units significantly reduced on-site waste and energy consumption. The building envelope features high-performance insulation, including Trima panel cladding, mineral wool in the walls and floors, and a Kingspan insulated roof system, contributing to superior thermal efficiency.
Energy-efficient LED lighting was installed throughout, and mechanical ventilation with heat recovery helps reduce energy demands while maintaining indoor air quality. A Trend Building Management System (BMS) optimises HVAC operation, including night setback functions to reduce energy use outside working hours.
Where possible, existing materials were reused, including redundant lockers from the previous facility, reducing demand for new resources. Approximately 1,000 cubic metres of excavated soil were relocated to another area within the site, avoiding the need for off-site disposal and reducing associated transport emissions. In line with planning conditions, the project also delivered biodiversity enhancements through the planting of wildflowers, hedgerows, and new tree planting along the facility’s boundaries.
This project exemplifies BES’s capability to deliver technically complex, high-compliance laboratory environments utilising modular build methodologies, successfully overcoming both technical and logistical challenges while prioritising sustainability, health and safety, and client continuity.
