Case Study

Hunter Safety Group Appointed Principal Contractor and Designer for AB InBev's Magor Facility Upgrade Project.

Hunter Safety Group was appointed by AB InBev to act as both Principal Contractor and Principal Designer for a major factory upgrade at their Magor facility, delivering a large-scale extension to increase production capacity. The project involved constructing, in two stages, a new two-storey building of approximately 10,000 sqm gross external floor area, with a 4,500 sqm footprint and a height of 16.1 metres, positioned in close proximity to existing operational buildings. The new facility incorporated a state-of-the-art filling line as its central feature, alongside a new warehouse and associated operational spaces.

The works encompassed several complex elements, including the removal and reinstallation of two CO? storage tanks, the rerouting of the existing site access road to allow construction on a former lorry park, the complete build of the ground floor and mezzanine levels, and the delivery of all associated external works. The project also included the installation of a new filling line with all necessary process and utility infrastructure.

Role

As Principal Designer, Hunter led an intensive pre-construction phase, managing design safety for multiple interdependent project components. This involved maintaining a live Design Risk Register to capture all design changes, assess associated risks, and ensure hazard elimination or risk reduction measures were implemented. Their input was pivotal in integrating safety considerations into the relocation of CO? tanks, access road realignment, building extension design, and filling line installation.

As Principal Contractor, Hunter oversaw the full coordination of contractor activities on site, spanning major civils, utilities, steel erection, and mechanical and electrical installations. Operating in a high-traffic, live manufacturing environment, they ensured that all works were sequenced and executed without risk to health and safety, while minimising disruption to ongoing production.

Summary

Through the integrated Principal Designer and Principal Contractor approach, Hunter Safety Group ensured the safe, efficient, and compliant delivery of this high-profile industrial expansion, supporting AB InBev’s goal to enhance production capacity while maintaining the highest standards of health, safety, and environmental performance.