King & Moffatt Offsite — Prestige Automotive Manufacturing Expansion

King & Moffatt were appointed as MEP contractor for the expansion of a world-renowned prestige automotive manufacturing facility in the south of England, a project that demanded precision, programme certainty, and absolute operational continuity on a live, continuously producing campus.

The expansion involved the construction of several new buildings to the east of the existing plant, including a major multi-function building housing Paint Shop, Logistics, Leather Shop, Analysis, Assembly and Distribution operations; a new Ancillary Building accommodating the on-site fire station and incoming HV supply; a Gate House and Waste Facility; a surface car park; and a cold hall structure to shelter vehicles within the Assembly process. The scale and complexity of this programme combined with the sensitivity of a live manufacturing environment made a traditional site-based MEP approach fundamentally unviable. Any disruption to operations carried significant commercial and reputational risk for the client, and the performance specifications for the LTHW and CHW distribution systems critical to Paint, Assembly, and Analysis operations demanded factory-level accuracy that only a purpose-built offsite facility could consistently deliver.

King & Moffatt Offsite's response was to develop a comprehensive offsite fabrication strategy centred on eight major prefabricated modules: Low Temperature Hot Water pump skids, Chilled Water pump skids, heating skids, and bespoke bracketry support systems for electrical containment and mechanical pipework across the new buildings. Each module was engineered, fabricated, pressure-tested, and pre-commissioned within our 40,000 sq ft manufacturing facility in Carrick-on-Shannon before being transported to site for final connection.+

Central to the success of this approach was King & Moffatt's in-house BIM team, who produced fully coordinated, clash-free fabrication drawings for every module. The client was invited to the facility at structured review milestones to assess progress firsthand, supported by sessions in our immersive 3D visualisation room enabling stakeholders to interrogate spatial relationships, installation sequences, and systems integration in a fully rendered environment before a single component reached site. This level of transparency and collaborative engagement is simply not achievable through traditional site-based delivery.

A dedicated Offsite Co-ordinator served as the critical link between the fabrication facility and the live construction site, continuously aligning fabrication progress, delivery sequencing, crane lift scheduling, and installation readiness ensuring each module arrived at precisely the right moment and transitioned seamlessly into the installation programme.

The outcomes were transformational. Approximately 12,000 on-site labour hours were eliminated from the construction programme, representing €1,000,000 in project value. All eight modules were delivered with zero significant commissioning defects, directly supporting reliable, energy-efficient long-term operation. Carbon emissions were meaningfully reduced through factory-based consolidation, fewer vehicle movements, and minimised on-site waste. The parallel fabrication of all eight modules while civil and structural works progressed on site compressed the overall programme, removing the traditional sequential dependency between structural completion and MEP commencement directly de-risking the client's production ramp-up timeline.