The Challange
The client set an ambitious brief to design and deliver a 100 mbar blast-rated laboratory building that combined structural resilience with operational functionality. The facility was required to accommodate 17 precision-engineered steel modules, creating approximately 560 m² of high-performance space to support critical operations. Internally, the building incorporated a laboratory, control room, feed area, and plant room, all designed with shelter-in-place capability to protect personnel during extreme events.
In addition to the main structure, a six-module non-blast-rated mezzanine was designed adjacent to the building, providing essential access and support for HVAC systems critical to maintaining operational integrity.
The project scope covered the complete structural design, including superstructure design for all modules, performance specifications for blast-rated doors and windows, lifting analysis, hold-down systems, transit frames, and a robust substructure design comprising piles, pile caps, and ground beams. A comprehensive structural Revit model was developed, supported by detailed general arrangement drawings and fabrication-level steelwork and foundation details.
The project was further complicated by challenging site conditions. The brownfield location presented poor ground conditions, existing buried services, and tight spatial constraints. In addition, the requirement for large open spans of 12.15 metres placed significant demands on the roof structure and connection design, requiring a high level of engineering precision and structural performance to meet both blast resistance and operational requirements.
The Solution
To ensure the facility met demanding blast-resistance performance requirements, a single-degree-of-freedom (SDOF) analysis approach was adopted in line with industry best practice and recognized standards, including ASCE guidance and PIP STC01018. This ensured that structural performance criteria were robust, defensible, and fully aligned with blast design expectations.
Working in close collaboration with the wider project team, a fully coordinated superstructure and substructure design was delivered. Through the use of Revit-based modelling and a modular steel construction strategy, the design enabled accelerated fabrication, improved quality control, and a highly efficient construction programme.
Specialist coordination was also undertaken with suppliers of blast-resistant doors, windows, dampers, and louvres, ensuring that all protective elements were fully integrated into the design and delivered consistent, high-performance resilience over the facility’s operational life.
Challenging ground conditions necessitated a strategic foundation solution. A piled foundation system was identified as the most suitable approach, supported by comprehensive preliminary design development. Close collaboration between geotechnical and structural disciplines enabled optimisation of pile layouts, preparation of detailed specifications, and technical review of contractor proposals. Constraints including limited land availability, existing buried services, and civil works interfaces were carefully managed to ensure a safe, efficient, and buildable solution.
From concept through delivery, Petro Safe acted as a trusted technical partner, maintaining momentum across all project stages and meeting key programme milestones. The team adapted design development to fabrication priorities and construction sequencing requirements, ensuring continuous progress throughout delivery.
On site, Petro Safe provided hands-on technical assurance, supporting substructure works and carrying out detailed reviews of fabrication drawings to ensure compliance with specifications and design intent. This proactive and quality-focused approach safeguarded performance under challenging conditions and supported successful execution of the works.
As of late 2025, modular fabrication is underway and groundworks construction has been completed, marking a significant milestone toward delivery of a high-integrity, blast-resistant laboratory facility offering long-term operational reliability.