Warringtonfire
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Location: Warrington
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Sector: Fire testing
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Division: Regional Building
Tilbury Douglas successfully delivered Warringtonfire’s fire resistance testing laboratory at Birchwood Park, Europe’s largest fire testing facility.
Completed six weeks ahead of schedule, the state-of-the-art laboratory significantly enhances fire safety testing capacity, ensuring faster and more rigorous certification of construction materials. Designed to support compliance with the Building Safety Act, the facility features cutting-edge fire testing furnaces, confidential test preparation areas, and a dedicated temperature controlled environment to enhance accuracy and repeatability.
Tilbury Douglas’ integrated working model, combining construction and MEP expertise, optimised coordination, cost efficiency, and risk mitigation. By tripling testing capacity, the facility plays a critical role in helping manufacturers meet evolving fire safety regulations, reinforcing the UK’s leadership in fire safety innovation.
This highly technical project involved constructing a world-class fire resistance testing facility, equipped with advanced fire furnaces, smoke abatement systems, and hydrogen-ready infrastructure to support future sustainability goals. The design included secure viewing areas to ensure data confidentiality for clients and a cutting-edge flame detection system to improve testing precision.
Tilbury Douglas worked closely with Warringtonfire, regulatory bodies, and specialist suppliers to create an environment that meets the highest industry standards for fire resistance testing.
At a glance...

£21m
Project value

2024
Completion date

Element Materials Technology
Client
Challenges and solutions
The complexity of the project, particularly the integration of highly specialist Mechanical, Electrical & Plumbing (MEP) systems, required meticulous planning and execution. The facility’s reliance on sophisticated fire testing technology demanded precise installation and commissioning to ensure optimal performance.
Tilbury Douglas’ integrated working model, combining construction and MEP expertise, played a critical role in overcoming these challenges. By optimising coordination, cost efficiency, and risk mitigation, the team maintained quality standards while delivering the project within budget. A proactive approach to risk management, detailed pre-construction planning, and specialist contractor engagement ensured successful project execution ahead of schedule.
Added value
Social value and sustainability were central to the project’s success. Tilbury Douglas generated a £9.57m social value return on investment, with 77% of the total project spend directed to the local supply chain. The project also supported 329 apprenticeship weeks and provided 53 work experience placements.
A Net Zero 2050 strategy was embedded in the design, incorporating energy efficient ventilation, advanced smoke abatement technology, and carbon reducing construction methods. The site team avoided the use of diesel powered equipment, reducing overall emissions. Additionally, over 50 trees were planted as part of a local environmental initiative. By implementing sustainable solutions and prioritising local engagement, Tilbury Douglas ensured long term environmental and economic benefits for the surrounding community.
Our partners
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M&E Engineer: Hoare Lea
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Structural Engineer: BDP
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Architect: TP Bennett