Lakeland Dairies
Milk Intake Extension
Tusker delivered a complex, steel-led extension to Lakeland Dairies' milk intake facility — fabricating, lifting, and installing critical structural steel within a fully live, high-output dairy plant, with zero disruption to daily milk intake and zero safety incidents.
Client:
Lakeland Dairies
Service:
Service
Location:
Bailieborough, Cavan
The Project
Tusker was appointed to design, fabricate, and install critical structural and process-support steel for a major extension to Lakeland Dairies' milk intake facility in Bailieborough, Co. Cavan. The scope covered the partial demolition and extension of the existing milk intake canopy, a new entrance road and yard area, new staff and trailer parking, two new silo plinths, a new CIP bunded area, a surface water drainage network for the expanded hardstanding, an intake pipe bridge, an electrical switch room, an administrator room, and an extension to the effluent drainage network. Delivered under a fixed-price contract and winter programme, the project had to maintain uninterrupted plant operations throughout.
The Challenge
Installing significant steel structures — the intake canopy extension, silo support infrastructure, pipe bridge, and associated frameworks — within a constrained, fully operational facility
Coordinating lifting operations, access routes, and installation windows around live milk intake and tanker traffic
Maintaining hygiene control and continuous production throughout construction
Delivering to a fixed-price contract within a winter programme
Completing all works without a single health and safety incident
The Solution
Tusker adopted a phased delivery and installation strategy, introducing fabricated steel elements in sequence so lifting and assembly never interrupted daily milk intake operations. Structural steelwork, pipe supports, and associated components were designed and fabricated offsite, reducing on-site construction time, minimising congestion within the live facility, and enabling more accurate, consistent, and efficient installation.
Daily coordination with Lakeland Dairies' operations team and tanker drivers kept lifting operations and access routes aligned with live production in real time, allowing risks to be identified and managed proactively. Tusker's in-house capability across steel fabrication, crane hire, haulage, and construction meant lifting, transport, and installation were all managed internally — tightening programme control and removing the interface risk that typically comes with coordinating multiple subcontractors.
The Result
Delivered on time and within budget, with zero health and safety incidents throughout. The completed steel structures now form the backbone of a modernised intake facility, supporting increased processing and storage capacity, improved traffic flow through a new one-way system, and enhanced operational safety across the site.
Project Team
Tusker — Main Contractor & Project Management
Tusker Steel Fabrication Division — Structural steel design support and fabrication
Tusker Crane Hire Division — Lifting operations and installation
Tusker Haulage Division — Logistics and transport coordination
Tusker Construction & Civil Works Teams — Site works, infrastructure, and build delivery
Lakeland Dairies — Project Team
Malone O'Regan Consulting Engineers — Civil and structural engineering design