BCD Charleville

BCD in Charleville is a specialist manufacturer of tanks and process vessels for the pharmaceutical industry — a sector where quality, precision, and regulatory compliance are not aspirations but requirements. Their facility in Charleville is a large-scale, high-bay workshop environment, purpose-built to handle the manufacture and testing of complex pharmaceutical-grade equipment.

Fergal Warren Mechanical was appointed to deliver the full mechanical services package for the facility, working within the unique physical and technical constraints of a building designed around overhead gantry cranes and very significant working heights.

The scale and configuration of the building presented an immediate and serious design challenge. With gantry cranes operating throughout the facility at height, the entire mechanical installation — pipework routes, distribution systems, service runs, and equipment positions — had to be designed and installed to work around the crane envelope without compromising access, safety, or system performance. This required careful coordination with the structural and crane engineers from an early stage and a precise, detailed installation approach throughout.

The technical specification of the mechanical services added further complexity. The facility required two distinct compressed air systems — a tool air network for general manufacturing use and a separate clean air network for process and quality-critical applications — each with its own design standard, filtration requirement, and distribution infrastructure. An RO purified water system was also required, demanding the high level of attention to detail and system integrity that pharmaceutical-adjacent environments demand. The hot water system incorporated a full Legionella prevention flush programme, and fire protection across the building had to be designed and installed to cover the full extent of a large, high-bay industrial space.

Fergal Warren Mechanical approached the installation with a detailed methodology that addressed the gantry crane constraints at the planning stage, establishing clear service zones and installation sequences that kept the mechanical works clear of the crane envelope at all times.

The two compressed air networks were installed as fully separate systems, each commissioned and tested to its own specification. The clean air network was designed, installed, and commissioned to deliver the filtration levels and system integrity required for its process-critical application. The RO purified water installation was carried out with the high level of material quality and installation precision these systems demand, with full pressure testing and documentation on completion.

The natural gas system, fire hose reels, fire suppression installation, and fire extinguisher programme were all delivered in compliance with the relevant standards and the building’s specific risk profile. The hot water system was completed with a full Legionella prevention flush, ensuring the facility met its water safety obligations from day one.

The result was a complete mechanical installation delivered to the exacting standards of a facility that serves one of the world’s most regulated industries.