SIKA
Ai Process Design, Construct & Commission a New ATEX-Compliant Prepolymer Reactor Plant for Leading Construction Chemicals Manufacturer, Sika.
Client:
SIKA
Industry:
Building & construction chemicals
Project Site:
Leeds, UK
Objective:
Design, construct and commission a new ATEX-compliant prepolymer reactor plant.
Sika Ltd is a global leader in construction chemicals, specialising in high-performance products including sealants, adhesives, waterproofing systems, and specialty polymers used across infrastructure, commercial, and industrial construction markets. To support growing demand for advanced prepolymer-based formulations, Sika required a new dedicated reactor plant capable of safely handling flammable liquids while delivering consistent, repeatable product quality. The project required specialist expertise in hazardous area design, bulk chemical storage, and integrated process automation.
Ai Process was appointed as an EPCM contractor to deliver a fully turnkey solution—covering engineering design, procurement, construction, installation, and commissioning—while ensuring compliance with ATEX regulations and minimal disruption to ongoing site operations.
Ai Process Scope of Works
Ai Process delivered the project on a full turnkey EPCM basis, including:
- Front End Engineering Design (FEED), detailed engineering, and process calculations
- Design and construction of a new ATEX-rated prepolymer reactor plant
- Bulk chemical storage and flammable liquid storage system design, including tank farm infrastructure
- Supply, installation, and commissioning of reactor vessels, storage tanks, pumps, filters, and utilities
- Full process control system design, PLC/SCADA, HMI integration, and recipe management
- Hazardous area classification, ATEX compliance, and safety systems integration
- Civil, structural steelwork, mechanical, electrical, and instrumentation installation
- Testing, calibration, commissioning, and operator training
Outcome and Benefits
Increased Production Capacity and Volume Expansion
The new 10,000-litre prepolymer reactor plant significantly increased Sika’s production capacity, enabling higher throughput and improved responsiveness to market demand. Enhanced bulk liquid storage, optimised material transfer systems, and automated batching removed previous bottlenecks, allowing the site to scale output efficiently while maintaining tight process control across all production campaigns.
Full ATEX Compliance and Enhanced Process Safety
Ai Process designed the facility in accordance with ATEX hazardous area classification standards, HSG 176 guidance, and flammable liquid storage regulations. Integrated safety systems—including gas detection, pressure relief, SIL-rated instrumentation, and controlled hazardous area zoning—reduced operational risk, improved workforce safety, and ensured long-term regulatory compliance for handling volatile and flammable chemicals.
Improved Process Efficiency, Automation, and Product Consistency
Advanced process automation, recipe-driven control, and real-time data visibility improved batch accuracy, repeatability, and traceability. Automated dosing, vacuum systems, and controlled thermal media circuits reduced manual intervention, minimised process variability, and delivered consistent prepolymer quality—directly addressing common construction chemicals manufacturing challenges around yield, waste, and rework.
Future-Proofed Infrastructure and Business Resilience
The plant was engineered with scalability and resilience in mind. Modular utilities, oversized services, and adaptable process control architecture allow for future capacity expansion, new product formulations, and additional tank farm services. This future-ready design strengthens business continuity, reduces capital project risk, and supports Sika’s long-term growth strategy in the construction chemicals sector.
