Forgemasters

The project forms a key part of the transformation of one of the UK's most strategically important manufacturing facilities and will support the production of specialist steel components for critical defence and industrial applications.

At the heart of the development is a new 30,000m² machine shop housing some of the largest and most complex manufacturing equipment in the country. To support these specialist machines, Careys is delivering a highly engineered substructure package over a two-year programme, including the construction of bespoke machine base foundations and extensive internal and external reinforced concrete slabs.

In total, the works comprise approximately 45,000m³ of reinforced concrete, requiring meticulous planning, technical expertise and close coordination across multiple stakeholders. The scale and complexity of the machine bases demand exceptionally high standards of accuracy and quality to ensure they can accommodate the significant loads and operational requirements of the manufacturing equipment they will support.

As specialist civil engineering partners, Careys has played a key role in unlocking this challenging site and enabling the successful delivery of the wider development. Working closely with McLaughlin & Harvey and Sheffield Forgemasters, the team has established a collaborative approach that has ensured efficient site coordination, programme certainty and the safe execution of works.

Once complete, the facility will enhance the UK's advanced manufacturing capabilities and strengthen the nation's industrial and defence infrastructure. The project demonstrates Careys' ability to deliver large-scale, technically complex civil engineering solutions on nationally significant developments, helping create the foundations for the next generation of British manufacturing.