Project Maya - Element 6

Project Description:
Element Six is a global leader in the design, development, and production of synthetic diamond and tungsten carbide supermaterials. It is part of the De Beers Group, with primary manufacturing facilities located in the UK, Ireland, Germany, South Africa, and the United States. These advanced materials are used in cutting and grinding applications across a wide range of industries.

Project Maya comprised the installation of industrial diamond presses for both primary and secondary manufacturing processes, along with associated support spaces, at the Element Six site in Shannon, Co. Clare. Located in Shannon Free Zone West, the site is bounded by Shannon Airport to the west and has road frontage to the east.

Ethos Input:
This redevelopment delivered a manufacturing facility for the processing of PCBN, PCD, and Amborite materials. The process begins with the synthesis of raw materials in a clean, stable pre-manufacturing environment before being placed in a high-pressure press.

Post synthesis, grinding, testing, and finishing of the final product are carried out in a dedicated processing space. The presses were housed in a high-bay portal structure, complete with crane infrastructure and pits. A dedicated pre-synthesis area provides enclosed, clean working environments, including rooms designed to meet cleanroom standards as required by the pre-manufacturing process.

Unique Key Features:

New mechanical services provided include the following:
• Ventilation and air conditioning systems.
• Dust extraction systems.
• Vacuum systems.
• Centralised Hydraulics System.
• Natural gas.
• Lab gases.
• Compressed air.
• Process cooling.

New electrical services provided include the following:
• MV / LV distribution.
• Fire alarm and protective services systems.
• General services power.
• Lighting and emergency lighting.
• Data and communications.
• Access control and CCTV.
• Automatic controls / BMS installation.