Sector: Process Industries

Blast Proof Office & Warehouse Facility - Phillips 66

  • Location: Humber Region
  • Client: Phillips 66
  • Duration: 47 weeks
  • Consultants: Frank Shaw Associates, Alan Wood & Partners, A E Thornton Firkin

Clugston was selected as the principle design and build contractor for this project due to its experience and detailed understanding of the critical requirements and demands of working in the petrochemical industry including a detailed understanding of the COMAH Regulations.

The nature of the project was to relocate the client's office staff to a central location, thus taking them out of the chemical plant to one main building on the permiter of the stie.

External works included a new access road linking avenue with car park, hard standings and lay down areas, security fencing, gates, turnstiles and bollards. Services included steam, electrical power, data, alarms, CCTV, drainage and water supply.  The project has provided the client with three zones within the facility.

  • Office Zone - blast lobby, open plan office areas, conference and meetings rooms, cafeteria, breakout rooms, locker changing and shower areas, copier rooms and data room.  The facilitiy also includes a toxic refuge area for employees to gather if an air tight hazard was to occur on site.
  • Workshop Zone - seal surgery, lapping room, analyser workshop, instrument workshop, tool store, fabrication and welding area and two overhead cranes.
  • Warehouse Zone - racking and tornado units, mezzanine level, first floor office


Robustness of the facilities design was critical with the underlying design requirement being of that of a blast proof facility. Therefore, design and construction methods and procedures had to reflect this. The glass, bricks and cladding of the facility are all constructed to high blast proof overpressure specifications in a double layer system with methods such as extra brick ties adding strength to the building. The design of the foundations of the building had to be considered in relation to main water supply flowing directly under the newly constructed facility.

Special Considerations

Despite this project not being constructed within the main plant area, the normal regulations for projects within a petrochemical environment were still applied. Clugston’s Health & Safety Manager therefore agreed a suitable method of integrating Clugston and client procedures with a bridging document which mutually agreed methods of working. Clugston also employed a full time Health & Safety Advisor on site to ensure that the client’s stringent specification and requirements were fully met.

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