WITH OPERATORS across the UK’s energy and process industries facing increasing pressure to deliver projects more quickly and efficiently, while maintaining safety standards, offsite fabrication is playing an increasingly important role in modern project execution.

Driven by tighter schedules, cost pressures and the need to minimise on-site risk in complex operating environments, pre-assembled systems and controlled workshop delivery is reshaping how major infrastructure projects are executed. Industrial services provider Bilfinger is supporting this evolution with the dedicated fabrication capabilities at its Unit 31 facility in Ellesmere Port, Cheshire.

Why more projects are moving offsite

"Offsite fabrication allows more work to be completed in a controlled setting, which ultimately reduces risk on site," said Philip Harrison, workshop manager at Unit 31. "It also gives greater confidence in installation, as systems are assembled, tested and quality-assured before they reach site."

The 20,000 sq ft facility forms a key part of Bilfinger’s integrated engineering and maintenance offering, supporting the delivery of pipework and pre-assembled systems across sectors including oil and gas, chemicals, power, nuclear and utilities.

Designed to operate within highly regulated environments, the workshop is configured across three dedicated fabrication bays, with full segregation between carbon steel and stainless-steel work. This ensures compliance with quality requirements while enabling flexibility across a range of material specifications. The facility is equipped with overhead lifting capabilities of up to 10 tonnes, enabling the safe handling of large and complex components.

Building certainty into complex projects

The growing use of offsite manufacturing to improve overall project outcomes is becoming a defining feature of modern fabrication strategy. This is increasingly supported by advanced digital technologies. 

Bilfinger is using 3D laser scanning to transform piping fabrication. By replacing slow, error-prone manual measurements with high-fidelity point clouds it is possible to achieve millimetre-level accuracy. This ensures that prefabricated pipe spools, valves and structural supports fit seamlessly upon delivery, eliminating expensive field rework and cutting pipeline downtime during installation.

By delivering pre-assembled pipework and modular systems within a controlled workshop environment, contractors can significantly reduce reliance on on-site fabrication, often one of the most challenging and risk-intensive phases of a project.

This approach offers several advantages including shortened project timescales through parallel working; reduced on-site congestion and associated safety risks; and greater predictability in installation and commissioning. For operators working in complex or high-hazard environments, these benefits translate directly into safer operations and more efficient project delivery.

Transforming project delivery

"We’re seeing a clear shift in how projects are being delivered across the sector," explained Harrison. "Clients are looking for greater certainty around quality, safety and programme, and that’s where offsite fabrication is adding real value, particularly in more complex or regulated environments."

As the UK’s industrial base continues to evolve, fabrication capabilities are playing an increasingly important role in enabling both traditional infrastructure and emerging energy transition projects. Facilities such as Unit 31 are well positioned to support this shift, providing the technical capability required to deliver complex systems while maintaining both safety and quality standards.

For more information: 

www.bilfinger.com

Tel: 0151 355 3035