Structural Steel Fabrication, Ireland | Hayes Mechanical & Engineering

Structural Steel Design, Fabrication & Installation - Foxford, Co. Mayo

FOXFORD BOXING CLUB

Hayes Mechanical & Engineering delivered the complete structural steel package for the new Foxford Boxing Club building in County Mayo – managing the full project lifecycle from initial 3D engineering design through to in-house fabrication, surface treatment, and on-site installation.
The project involved the design, fabrication, and erection of a hot-rolled structural steel portal frame building measuring 30 metres by 10 metres, with a distinctive curved apex roof profile. All structural steelwork was fabricated to specification at our Co. Mayo workshop before being delivered and erected on site by our experienced installation team.
From the initial Advance Steel 3D structural model through to the application of the final 80mm insulated panel cladding system, every phase of this project was delivered in-house by Hayes Mechanical & Engineering – giving the client a single point of accountability, a quality-assured fabrication process, and a completed building that is built to last.

Full structural steel package - design, fabrication, and installation
Hot-rolled portal frame structure - 30m × 10m footprint
Curved apex roof profile - clear internal span of 10 metres
In-house Advance Steel 3D design and fabrication drawings
Steelwork fabricated, primed, and painted in our Co. Mayo workshop
80mm insulated panel cladding system installed to all elevations
Delivered entirely by the Hayes Mechanical & Engineering team

Client:

Foxford Boxing Club

Location:

Foxford, County Mayo, Ireland

Category:

Structural Engineering

Every phase of this project - from the engineering model to the finished building - was delivered by our in-house team.

What We Delivered

3D Engineering Design & CAD Modelling

Prior to any fabrication commencing, our engineers produced a fully detailed 3D structural model of the complete frame — including portal frames, purlins, side rails, bracing systems, and all connection cleats. Fabrication drawings were generated directly from the model, ensuring every component was pre-engineered and ready for efficient workshop production and on-site assembly.

Steel Fabrication & Surface Treatment

All structural steelwork was fabricated in-house at our Co. Mayo workshop. The steel members were hot-dip primed and finish-painted in Anthracite Grey prior to leaving the workshop — ensuring a consistent, high-quality surface treatment across every element before delivery to site. In-house fabrication means tighter quality control, faster programme, and no third-party reliance

On-Site Erection & Cladding Installation

Our erection team assembled the full structural steel frame on site — portal frames, purlins, side rails, and X-brace systems — bolt-fixed to pre-installed base plates set in concrete foundations. Following frame completion, the building envelope was finished with 80mm insulated panel cladding, personnel doors, and high-level window openings, delivering a fully enclosed, insulated, and weathertight building

Our Project Delivery Process - Foxford Boxing Club

How We Worked (Numbered Process Steps)

1. Brief & Engineering Design

We reviewed the client's building requirements and produced a fully detailed 3D structural model - capturing all portal frames, purlins, side rails, bracing systems, and connection details. Fabrication drawings were generated directly from the model.

2. Workshop Fabrication

All structural steelwork was fabricated in-house at our Ballintubber, Co. Mayo workshop. Every member was cut, drilled, and welded to the fabrication drawings, then hot-dip primed and painted in Anthracite Grey before leaving the workshop.

3. Site Preparation & Foundations

With the steelwork ready in the workshop, the site team coordinated with the groundworks contractor to confirm the concrete strip foundations and base plate locations were accurate and ready for frame erection.

4. Frame Erection

Our site erection team installed the full structural steel frame - portal frames, curved apex members, purlins, side rails, and X-brace systems - all bolt-fixed to the pre-installed base plates. The 30m × 10m frame was erected efficiently and accurately to the CAD model.

5. Cladding & Completion

Following successful structural frame erection, the 80mm insulated sandwich panel cladding was installed to all elevations and the roof, including personnel doors, high-level windows, profiled roof sheeting, and all matching trims and flashings. Building handed over complete.

Project Photography - Foxford Boxing Club

Project Gallery

Project Photography - Foxford Boxing Club

Project Summary & Results

1 m²

Total Building Area Delivered

1 x 10m

Portal Frame Footprint

1 mm

PIR Insulated Cladding System

1 %

In-House — Design to Installation

Talk to our structural engineering team. We cover projects across Ireland, the UK, and Europe - and respond to all enquiries within 24 hours.

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