Tipton-based Privilege Construction get Bilston process lines on track for Mueller Europe

Privilege Construction worked on the planning, design and construction of process line foundations and structural steel alterations for the Bilston factory of Mueller Industries, a US-based manufacturer of copper tube and fittings.

The project was part of Mueller Europe's restructuring of operations in the UK with the redistribution of some of the company's process lines in the North West to its plant in Oxford Street – the home of its Wednesbury Copper Tube business.

Privilege was launched just three years ago by managing director Frank Phillips, specialising in industrial construction work. Privilege has a core of around 10 staff who then work with a series of sub-contractors.

The Mueller contract took around six months, said Mr Phillips. "It was a very complex project, with restricted access we we worked around the continuing production at the plant during the construction process. That sometimes meant we had to work out of hours."

Before the start of work on the main Schumag production line foundation works at Mueller, Privilege Construction had to remove two main frame structural steel columns that supported the existing overhead cranes. New support framework was designed to omit temporary works whilst new columns and associated trussed frames were installed – with everything scheduled so that the plant's crane operations could remain in full production.

After reinforcing the existing foundations, a new structural steel frame was installed, which also supported a two-storey conveyor system. During this stage, Privilege Construction also (as part of its planning) diverted an existing 450mm storm drain, ensuring that it remained live until the new sewer and manholes were installed. Diverting the run was achieved without any over-pumping.

Due to restricted headroom and the working area bounded by the ongoing manufacturing processes, excavation operations were conducted by a line of three-ton mini-diggers. As the ground was reduced down to its forming level, bases, beds and pits were constructed in sections, working over a four-phase system.

All materials had to be craned in and all concrete operations were pumped as works progressed. On completion of the foundation works, the Schumag production process lines were installed, lined and levelled, followed by the grouting of all the holding down bolt pockets and bases plates.

Mueller Industries' plant director, Paul Smith, said: "Despite the many access obstacles that they had to tackle during the contract, Privilege Construction carried everything out in a very organised and methodical manner."

In addition to the construction, Privilege Construction assisted in the planning of the process lines - and at pre-construction stage, conducted various investigations of existing services, ground conditions, structural steel frame and previous foundations.

After completion of the detailing process machine layouts, Privilege Construction designed the reinforced concrete foundation beds, inclusive of all the service ducts and all the ancillary bedments for the service plant.