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Case studies

Knutsford to Bowden Road Improvement

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Bouygues Energies & Services secured a partnership to implement a scheme designed to improve 7.5km of the A556 trunk road between Knutsford and Bowden, creating a modern dual carriage way.

29,000m

duct installed.

0 accidents

The fundamental requirement of this project was to; improve road safety, reduce journey time, and minimise environmental impact in the surrounding areas.

Our Solution

To power the new communication systems, we installed, tested and commissioned all of the equipment cabinets, power and local cables. 

  • Installed and commissioned detector loops into the road surface which interface with the Motorway Incident Detection Automatic Signalling (MIDAS) system
  • New ducting infrastructure including chambers,emergency roadside telephone bases, cabinet plinths, hard standings, footpaths, steps and handrails
  • Retaining solutions on cuttings and embankments around cabinet and chamber sites
  • New power supply bases and plinths, including power cabinets
  • Advanced Motorway Indicators and bases
  • Communications network and associated civil engineering

 

Client Benefits

We worked electronically and utilised diaries

This helped to improve efficiency, minimise costs and reduced environmental impact, streamlining processes and reducing risk. 

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Case studies

Kent County Council Energy Saving Scheme

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In 2016, Bouygues Energies & Services partnered with Kent County Council to reduce street lighting energy consumption in order to meet the challenge of rising energy prices. To achieve this Kent County Council aimed to convert all of its current street lights to Light Emitting Diode (LED) products.

£4m

energy savings

120,000

new street lighting units

Mike Whiting, Kent County Coucillor: "The decision to work with Bouygues E&S was based on the experience of their previous successful projects and our confidence that they had the right abilities to complete the project to an exemplary standard, while also addressing environmental challenges"

The overall aim of this project is to reduce energy consumption by at least 60% whilst maintaining lighting standards in accordance with BS5489: 2015. The project work, to install LED lanterns, started in March 2016 and will be delivered in three phases:

  1. In the first 14 months, 75,000 residential lights will be changed
  2. Over 24 months, approximately 45,000 major road and town centre street lights will be changed
  3. Ongoing maintenance of the assets for the duration of the contract

Our Solution

Bouygues Energies & Service designed an award winning project delivery plan which brought together strategic programming, smart logistics and a dedicated mobile workforce.

We delivered an energy focused design solution and guaranteed Kent County Council more than 65% in energy savings. This drove down their costs and increased their overall efficiency.

To ensure ease of monitoring, we have chosen a proven, reliable system which meets all of Kent County Council’s needs and has the in-built ability to offer future “Smart City” capabilities. Providing 100% connectivity for all street lights, all the newly installed units are linked to a central management system (CMS) which will allow Kent County Council to manage and adapt lighting levels as required.

Installation crews are managed by supervisors based in mobile welfare/office vehicles. This ensures safety, productivity and quality, and gives us better control of operations with supervisors based close to the works.

Client Benefits

Whilst still in the early stages of this contract, Kent County Council have experienced numerous benefits through its partnership with Bouygues Energies & Services.

The Local Authority's investment is guaranteed

This is a result of the underwriting of energy and maintenance savings.

The smart logistics approach has enabled an accelerated programme option

Part of our winning strategy was designing an accelerated delivery programme for the LED conversion. By delivering this scheme in 25 months instead of 38 months, additional savings of £4m will be generated.

Average savings of £4m a year

The Council saves money and reduces its carbon footprint by lowering energy usage. Our LED conversion guaranteed saving 65.7 % of Kent’s street lighting energy thereby reducing the carbon footprint.

Maintenance costs will be reduced

We offered KCC an annual lump sum maintenance package - saving Kent County Council an estimated £1.6 million over 15 years and transfers the risk of any increased maintenance costs over the life of the contract to Bouygues.

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Case studies

Operational Computer Room Refurbishment and Upgrade

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Following a successful track record in working with Airbus Defence and Space, on a number of major projects, Bouygues Energies & Services were appointed to deliver the refurbishment of this 1500m2 operational computer room.

1,500m2

operational space

2 x 500

kVA UPS units at N+1

2 x 800

kVA sychronised generators

Our Solution

The project required the replacement of existing critical services whilst the facility remained operational. The works included the replacement of the computer floor, which had been contaminated by zinc whiskers. We installed new air conditioning and power and through our design, provided additional capacity and resilience.

The service included:

  • 2 x 500 kVA UPS units at N+1
  • 2 x 800 kVA synchronised generators
  • A&B supply to PDUs and Rack
  • A single press double knock emergency power down facility with fault monitoring.

Critically, we achieved a seamless transfer of IT data equipment from the existing UPS and distribution systems.

Benefits to the Client

A Single Point of Contact to Boost Performance
Providing detailed design, architectural, procurement, installation, mechanical & electrical services, and Integrated System Testing (IST) to offer seamless engineering solutions to the challenges facing our client.

Minimal Downtime
Due to our experience in Live Operational Site developments, the data centre was able to be refurbished whilst remaining operational.

Longevity Through Design
Through innovative and forward thinking design, we refurbished the existing facility whilst also adding resilience to the main data centre.

Our Commitments - Data Centre

Our Commitments

Performance

Delivering the highest level of efficiency, resilience and industry leading PUEs

 

 

Scalable

Tailored solutions which meet the requirements of flexibility and modularity, supporting your growth strategy

 

Zero Downtime
Delivering the highest levels of availability for your infrastructure and assets

 

Sustainability
Integrating the latest technology and applications with sustainable design, to achieve BREEAM and LEED certifications

 

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Case studies

Cutting Edge Facility for the Welsh School of Pharmacy

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The Welsh School of Pharmacy was established in 1919 as part of Cardiff University; one of Britain’s leading teaching and research universities. In order to continue their progress in scientific development, the Welsh School of Pharmacy required the construction of a cGMP pharmacy suite which would include a cleanroom validated to EU GMP grade B to D classification.

12

student capacity

B to D

EU GMP grade classification

months fast track project

Client's Requirement

This new facility will help the school, not only to advance their teaching methods in the field, but also to replicate the manufacturing standards, processes and protocols expected in the pharmaceutical and life science sectors; enabling their students to better understand and appreciate regulatory requirements before they leave university.  

The intended educational purpose of the facility also required that the two areas – sterile and non-sterile – would accommodate up to 12 students at any one time.

Our Solution

Bouygues Energies & Services’ turnkey Design & Build solution included the stripping out and removal of an old optometry unit, in order to construct a new, fully-functioning unit which met the client’s specific requirements for use as a teaching facility.

The completed unit is capable of providing small-scale cytotoxic manufacturing support, as well as offering a high quality teaching environment, where both sterile and non-sterile areas are regulated to EU GMP grade B to D cleanroom classification.

The installation of temperature, humidity, filtration and pressure cascades were as per the stringent requirements for this type of facility, and were designed to be stand-alone from the central university services, increasing the reliability of the facility’s provisions.

Although the pharmacy suite was not required to be MHRA approved, we ensured that our commissioning and validation of the facility followed the key steps necessary to enable future regulatory approval, if required.

In order for the unit to be ready for the new term, our teams also had to undertake special considerations and planning; commencing the project during term time and arranging their work around end-of-year exams.

Client Benefits

A Single Point of Contact to Boost Performance
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Cutting Edge Facilities
A state-of-the-art and one-of-a-kind teaching facility in Wales, with the added value of small scale production capabilities if required.

Minimal Teaching Downtime
By considering the impact of works during the summer exam period, we were able to meet the new term deadline with minimal disruption to student’s end-of-year studies and minimal teaching downtime for the School of Pharmacy.

Future-proofed Delivery
The quality of our commissioning and validation will enable the Welsh School of Pharmacy to access MHRA approval for their facility in the future, if they wish to do so.

Increased Reliability Through Self Sufficiency
Equipment responsible for the environmental parameters of the facility were designed to run independently, negating any reliance on central university services.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

The Home Office

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Bouygues  Energies & Services works in partnership with the Home Office to deliver a full range of Facilities Management services from Building Maintenance and Lifecycle services through to reception, cleaning and reprographics. 

 

1700

Workstations added
increasing maximum capacity by 500

Since 2005 we have delivered Total Facilities Management to the Home Office under a long term concession agreement. Looking after 74,000m2 of high quality office space in central London, we have worked closely with our client to ensure that buildings meet the exacting service levels including its role in hosting over 10,000 visitors and high profile guests per month.  

Throughout our partnership, we have worked consistently with the client to ensure the building and services we deliver remain relevant to the evolving function and nature of the building users. 

In 2014, a further Government department had to be accommodated in the building, requiring workstation consolidation and an increase in capacity, ensuring efficiency and productivity were improved through agile working techniques. 

Our Solution

This was a unique project due to the wide range of constraints in integrating a Government Department within the Home Office FM service delivery model. The alterations and improvements included: 

  • Alterations and adaptations to the HVAC and electrical infrastructure
  • Building fabric alterations to include new ministerial suites, meeting rooms and open plan areas
  • Comprehensive change management
  • Adaptations and improvements to room/space booking management systems
  • Security pass management and new starter inductions. 

Client Benefits

Bouygues Energies & Services adopted the role of principal contractor

This provided a cost efficient contracting chain, therefore reducing cost to the client. 

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Case studies

Pharmaceutical Manufacturing Facility Expansion

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Our client are a leading provider of advanced technologies to pharmaceutical and biotechnology industries. With over 80 years’ experience, they specialise in the early development, clinical supply and commercial manufacture of pharmaceutical, biologic and consumer health and beauty products.

5000m2

building extension

HVAC

provisions

14

months fast track 

project delivery

In order to meet the growing demand for development, delivery and supply, our client required the design, construction and commissioning of a facility for the manufacture and packaging of freeze dried tablets.

Our Solution

Bouygues Energies & Services were appointed as the turnkey design & build partner for this specialist freeze-dried tablet and packaging facility. Given our extensive experience working within the pharmaceutical industry, our unique, in-house, multidisciplinary teams were able to provide a design solution which matched the highly particular requirements of the client.

The project delivery included the construction of a new 5000m2 building extension, as well as state-of-the-art cleanrooms and utility systems, with specialist purified water and gas systems. We were also responsible for the integration of solution preparation systems, lyophilisation, a nitrogen filling tunnel and the freeze-drying and secondary packaging equipment. Our solution also included provision of HVAC services and cleanroom fit out, to ensure the necessary environmental parameters were met and maintained.

Client Benefits

A Single Point of Accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Compliance Delivered on a Fast Track Basis
Our solution encompassed a facility which adhered to regulatory compliance, supporting their coveted position within the industry, whilst meeting project time restraints.

Cutting Edge Facilities Promoting Business Growth
World class facilities will help cement our client’s place on the global market; with clients across the globe, an international standard manufacturing base will aid in the retention of their current portfolio and help with its future growth.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

Replicating the Red Planet

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ExoMars is an international co-operative of the European Space Agency (ESA), Roscosmos and NASA. The ExoMars Rover is an automated vehicle, engineered and built by Airbus Defence and Space for the ESA. It is intended that it will be launched into space in 2020, following a scout mission by an orbiter and probe in 2016. The mission: to find evidence of past or present life on Mars.

300

tonnes of specially selected sand

2000

LUX lighting system

9m

wide control room glazing

Client's Requirement

To support the Mars Rover venture, Airbus Defence and Space required a state-of-the-art testing area – the Mars Yard – to simulate Mars’ terrains and conditions on their main site in Stevenage, UK. They required an indoor terrain, about the size of a basketball court, filled with 300 tonnes of specifically selected sand, complete with rocky obstacles which would mimic the appearance of a Martian landscape.

Our Solution

Airbus Defence and Space appointed Bouygues Energies & Services as their turnkey Design & Build partner for the delivery of Mars Yard. By working in close collaboration with the client, we were able to make every provision to ensure the facility replicated the Mars environment.

We ensured that the environment was highly controllable through the installation of ventilation and air conditioning, to maintain a temperature between 18 and 25 degrees. We also installed an external AHU with a high quality fabric air distribution duct to distribute air uniformly, without disturbing the fine sand terrain; and an ultra bright 2000 lux lighting system, to simulate typical light levels on Mars. The indoor floor surface was designed to a reddish-brown colour, in imitation of the Red Planet, and this was complemented by a large mural of the Martian landscape.

Our service included the construction of a unique, open grid ceiling, allowing suspension of services and a target grid system for the Mars Rover, as well as the installation of an elevated secure control room, built with 9m wide glazing and all necessary power and IT. This allowed a full view of the terrain area, enabling analysis of ExoMars behaviour such as drilling, roving and overall manoeuvrability.

Client Benefits

A single point of contact to boost performance
Working within a live operational site, we provided detailed design, architectural, procurement, construction, mechanical & electrical services and commissioning to deliver a one-of-a-kind world class facility.

Minimising environmental impact
By utilising existing building services, adapting them to new scope and layout, we minimised the financial and environmental impact that would have accompanied a Greenfield development.

User friendly and adaptable
The fully-fitted, elevated control room, built with the integrity of the environment in mind, will allow observation of the Mars Rover, without hindering or altering test results. Furthermore, the ability to alter environmental conditions means that the facility is highly adaptable to suit all manners of testing for the Mars Rover.

Cutting edge facility
The innovative project provides Airbus Defence and Space with a showpiece facility that will help develop the Mars Rover’s autonomous navigation, cementing their position in the aerospace field.

 

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Case studies

Additive Layer Manufacturing Facility

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Our client are one of the world’s largest, independent, first tier suppliers to the global aviation industry. Drawing upon over 100 years of aerospace experience, considerable knowledge and superior manufacturing technologies, our client supplies high-value, integrated assemblies in both metallic and composite materials.

21 

degrees (+/-1) control

<40%

RH

BMS

system

Client's Requirement

Our client required the construction of a controlled environment, advanced manufacturing area for their additive layer manufacturing (ALM) solutions. ALM is a process where components are created layer by layer, enabling complex structures to be produced directly from 3D CAD models; a game-changing development for the aerospace manufacturing industry.

Our Solution

Bouygues Energies & Services were appointed as the turnkey design & build partner for this project. Through a collaborative approach to the design, we delivered a ‘box within a box’ construction solution, using composite walls and ceilings. This met the client's requirement of an area built within the existing building, which would still remain independent from the building’s structure. All floors were levelled and finished to the standard of new areas, ensuring succinct amalgamation of the old areas with the new.

Our in-house design teams designed a full HVAC system to control humidity and temperature within the manufacturing area, managed by a networked BMS system. The design solution incorporated provision of close control temperature and humidity within the 21 degrees (+/- 2) and <40% RH.

Working within the live operational site, our team installed lighting levels, gases and compressed air in order to meet specific client equipment requirements. We tested and commissioned the facility before handover to ensure that high standards had been maintained throughout the project for prime client usability.

Client Benefits

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Cutting edge facility
The ALM process is the next step in efficient aircraft manufacture and the completion of this facility provides our client with the correct environment to utilise ALM, manufacturing ‘first of their kind’, additive layer aircraft components.

Innovative manufacturing capabilities
ALM capability will mean that lead times will be reduced, manufacturing will be more efficient and more innovative products can be created, improving prospects for both our client and theirs.

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Case studies

Critically Controlled Cleanroom Facility

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Our client required a bespoke facility, which would be purpose-built and highly controlled to ISO class 8 accreditation. All operations would need to maintain strict BioBurden control parameters, as well as be aware of the molecular and particulate contamination risks.

Steel

design

Class 8

ISO accreditation 

BioBurden

control parameters

Our Solution

Following previous experience of working in collaboration with our client, Bouygues Energies & Services were appointed as the turnkey design & build partner for this project.

Our track record of delivery for cutting-edge technology and mission critical projects enabled us to present a detailed solution that met the client's specialist requirements. By collaborating with their project management executives, our own team were able to fully identify and understand the requirements of the project and therefore offer a fully prescribed solution.

The full-height, stainless steel design comprised of a changing room, airlock, equipment support and preparation areas. In order to meet the paramount environmental demands, a molecular carbon filtration system and temperature and humidity controls were core aspects of the design.

Client Benefits

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Validated results
By delivering the project to strict regulatory standards, the facility is validated under the ISO classifications, allowing our client meet their own customer expectations.

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Case studies

National industry Biotechnology Facility 1

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The Centre for Process Innovation (CPI) helps its clients develop their products and processes from early and mid-stage development, with minimal risk and guided understanding of relevant cost contribution. To achieve this proof of scale testing, they required facilities which could accommodate a diverse range of biomass feedstocks and comprise of state of the art handling and preparation equipment.

downstream processing technologies 

10,000L

fermentation capability

DCS

control system

CPI appointed Bouygues Energies & Services as a principal contractor to design and build its pilot and demonstrator industrial biotechnology facility at Wilton Centre, Redcar. CPI required the detailed design, construction and commissioning of the bioprocessing facility, biolaboratories, cleanrooms, biotechnology processing equipment and clean/critical utility systems.

Our Solution

Bouygues Energies & Services’ in-house process engineering division are already responsible for the selection and integration of leading advanced laboratory technologies (HPGLC, GCMS, LCMS) and test instruments (NIR). Our consulting team were therefore well equipped to develop a conceptual and detailed design, based on CPI’s unique user requirements of creating highly flexible facilities and engineering systems that would help its clients de-risk their process development.

We designed and built bespoke and novel downstream processing equipment, such as oscillatory baffle flow reactors and high shear homogenisers. We ensured the facility was also supported by an advanced DCS control system for semi-automatic/fully automatic operation.

Client Benefits

A single point of contact to boost performance
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Efficiency delivered
A fast track delivery of world-class facilities, meeting budget constraints,  maximising the client's future profitability.

Financial savings passed on to clients
10, 10-750 and 10-10,000 litre scale fermentation vessels complement proof-of-concept testing and production at scale, enabling CPI’s clients to demonstrate processes, prior to expensive capital investment into full scale projects.

Knowledge exchange
The state of the art DCS systems are utilised for process controls and data capture for scale up, enabling worldwide interfacing and knowledge exchange with universities.