Bespoke Industrial Door Manufacturing Facility
Project Overview
Booth Industries, a specialist in high-performance bespoke and engineered door sets and manufacturer of the ballistic grade door that protects the entrance to no. 10 Downing street, constructed a dedicated new manufacturing facility to produce insulated, hydraulically operated doors for the British Antarctic Survey’s (BAS) Rothera Research Station in Antarctica. These specialist doors feature advanced thermal insulation, trace heating, and robust hydraulic functionality to endure extreme polar conditions while ensuring reliable performance for cargo and personnel access.
Barlows was appointed as the MEP contractor to deliver a complete Mechanical, Electrical, and Plumbing installation. This ensured the facility supported precision manufacturing processes in a controlled, efficient, and safe environment tailored to the exacting requirements of Antarctic-grade products.
Challenges
Producing doors for one of the world’s most demanding environments required meticulous control over production conditions, including temperature, humidity, material handling, and workspace illumination across expansive warehouse and manufacturing areas. Key MEP-related challenges included:
Providing safe, reliable power distribution for heavy industrial machinery, precision tools, and flexible workstation needs.
Maintaining consistent environmental conditions while optimizing energy use in large-scale spaces.
Incorporating adaptable power and lighting solutions that enhance safety, productivity, and efficiency in dynamic warehouse zones.
Achieving high energy efficiency, reduced operational costs, and compliance with UK regulations while supporting sustainable operations.
The facility’s design also needed to accommodate future scalability and integrate seamlessly with the building structure.
Solutions Provided by Barlows
Barlows delivered a comprehensive, turnkey MEP package customized to the facility’s specialist needs:
Mechanical Systems: Advanced zoned HVAC with heat recovery and smart controls to regulate temperature and humidity precisely, protecting sensitive materials during fabrication and assembly.
Electrical Systems: A robust power infrastructure featuring high-capacity distribution, energy-efficient LED lighting, and backup systems for uninterrupted production. To enhance safety and flexibility in the manufacturing environment—particularly at assembly and testing workstations—dedicated 110V power supplies were installed directly at workstations. This reduced reliance on step-down transformers for portable tools, minimized trip hazards from trailing cables, and aligned with common UK industrial practices for low-voltage hand tools and equipment. Throughout the warehouse and production areas, intelligent lighting systems were implemented using advanced LED fixtures integrated with motion sensors, daylight harvesting, and automated controls. These smart systems adjust illumination levels dynamically based on occupancy, natural light availability, and operational zones—ensuring optimal visibility only where and when needed while significantly reducing energy consumption.
Plumbing Systems: Efficient water supply, drainage, and industrial waste management solutions, including provisions for water recycling where applicable to support sustainable manufacturing.
Close collaboration with Booth Industries’ team and the use of BIM ensured clash-free coordination, precise integration, and systems designed for long-term reliability and ease of maintenance.
Results and Outcomes
The facility now enables Booth Industries to efficiently manufacture and test high-specification doors destined for BAS’s Rothera base, contributing to critical polar research infrastructure. Notable achievements include:
Enhanced workstation safety and productivity through integrated 110V power, reducing setup times and electrical risks.
Substantial energy savings and improved operational efficiency from the intelligent lighting throughout the warehouse, with automated adjustments minimizing unnecessary illumination and supporting lower utility costs.
Significant overall energy efficiency via efficient MEP design, contributing to reduced operational expenses and sustainability goals.
Successful on-time completion, allowing Booth Industries to fulfil their commitments to the British Antarctic Survey without delays.
Zero safety incidents during MEP installation and commissioning.
This project highlights Barlows’ expertise in delivering tailored MEP solutions for high-precision industrial manufacturing, ensuring operational excellence in specialized sectors with innovative features like intelligent lighting and workstation-specific power.
For more information on how Barlows can support your industrial or specialist project with innovative MEP services, contact us today.
