NovoGen Engineering Solutions was commissioned to deliver the mechanical design for a new (130,000 ft² floorspace) hot-dip galvanising plant on Sandholes Road, Cookstown, County Tyrone. The facility was developed to support high-capacity galvanising operations and includes the largest dual-fuel galvanising kettle in Europe.
The project required a fully coordinated mechanical design to support process operations while integrating safely within a busy industrial environment where overhead cranes and forklifts operate continuously.
The mechanical design included the integration of multiple plant systems such as underfloor heating, HVAC, compressed air distribution, LPHW boilers, mains water distribution, nitrogen pipework for kettle cleaning, natural gas supply and a range of process-related equipment required to support galvanising operations.
The project presented several complex engineering challenges due to the scale of the galvanising process and the operational constraints within the factory environment.
A key difficulty was designing and positioning mechanical services within a facility that relies heavily on overhead travelling cranes for material handling and frequent forklift movements at ground level.
Mechanical services had to be carefully routed to ensure they did not interfere with crane travel zones, lifting operations, structural elements, or operational access routes. In addition, the plant required integration with specialist galvanising process equipment supplied by multiple manufacturers. The key challenges included:
NovoGen Engineering Solutions provided a coordinated mechanical engineering design that carefully integrated all mechanical services and process support systems within the plant while maintaining safe operational clearances. A 3D model of the factory was created, and all services were input into the model.
The design process involved close collaboration with structural designers, contractors, and plant operators to ensure that all systems worked together efficiently and that interfaces with specialist galvanising equipment were properly coordinated.
Mechanical systems were carefully routed to avoid crane operational zones and forklift circulation routes. Detailed coordination ensured that services could be installed and maintained without impacting production operations or safety requirements.
The project also required integration with several specialist plant systems used in the galvanising process, including chemical storage and distribution systems, treatment tanks, rinsing and drying equipment. Corrosion resistant materials were used in the chemical treatment areas.
Through detailed design coordination and collaboration with equipment suppliers, all services and process systems were successfully integrated within the facility layout.
The completed design successfully integrated all mechanical services and process support systems within the operational constraints of the galvanising plant.
The project delivered a safe, efficient, and coordinated mechanical design that supports the facility’s high-capacity galvanising operations while maintaining safe working environments for plant personnel and material handling equipment. The 3D modelling ensured that all potential clashes of services were avoided at the design stage. The key benefits included:
NovoGen Engineering Solutions combines strong engineering expertise with practical industrial design experience. By working closely with project stakeholders and applying a coordinated design approach, we deliver reliable engineering solutions that meet the complex operational demands of modern manufacturing facilities.
