In October 2024, Whitehead commenced work in partnership with Powells on the £6 million transformation of an existing office building into a high-end manufacturing workshop and modern administrative facility for Senior Flexonics, part of the FTSE 250 Senior plc group.

This project aimed to create additional highly skilled jobs while delivering a facility that brings together advanced manufacturing, research and development, and a high-quality workplace environment within a single building, supporting both current operations and future growth.

All photo credits – Nick Smith nicksmithphotography.com

The scheme was supported by investment from Senior plc, alongside funding from the Welsh Government’s Economy Futures Fund and Caerphilly County Borough Council, reinforcing its importance to regional economic growth.

Originally constructed approximately 25 years ago on the former Oakdale Colliery. The 7,000m² steel-framed warehouse had previously been converted into a large office space.

This refurbishment approach also contributed to reduced embodied carbon by repurposing the existing structure rather than pursuing a full new-build solution.

Works involved a full mechanical and electrical installation, delivering a complete building services package tailored to meet the operational demands of a precision manufacturing environment. Our scope of works included comprehensive mechanical and electrical systems, fire alarm installation, Voice & Data infrastructure, HV/LV power distribution systems and a fully integrated security package. Each element was carefully designed and coordinated to ensure efficiency, resilience and compliance with industry standards, while supporting both production and office functions within the facility.

John Minnett, Project Manager for the scheme, commented:

“I am extremely proud to have been involved in such a prestigious project. We helped the client and their team visualise their concept through RIBA Stages 3 and 4 through to delivery and operation. We developed a collaborative approach where all stakeholders in the scheme had a voice and as a result, developed a solution that not only met their operational requirements but exceeded expectations.

Through strong collaboration, careful coordination, and a shared commitment to quality, we have created a facility that is modern, efficient and future-proof. I truly believe this building has the potential to be award-winning.”

Rob Vaughan, Managing Director of the Senior Flexonics Innovation Centre, said:
“This new Innovation Centre in South Wales will bring together cutting-edge manufacturing and design capabilities under one roof, supporting Senior Flexonics’ talented team as they develop highly engineered products for use in conventional internal combustion engine, hybrid & electric vehicle and powertrains. Senior Flexonics is proud of its long history in south Wales, where we have operated for over 30 years, we are committed to delivering excellent skills and training as well as well-paid employment opportunities in the area.”

The completed project provides Senior Flexonics with a high-specification manufacturing environment that supports productivity, safety, and long-term growth, alongside a professional and welcoming administrative space. It now regularly hosts international customers, investors and government representatives, reinforcing South Wales’ reputation as a hub for advanced manufacturing and innovation.