EXP CONSTRUCTION LTD is a controls engineering practice working from 18 Hollyhurst Road, Sutton Coldfield - B73 6SY, United Kingdom (GB). The team takes on control cabinets, programmable logic, factory networks and instrumentation loops that other contractors have walked away from, and it rebuilds them as one coherent integrated system. Whether you need a single panel refreshed or an entire production line brought back under modern supervision, this is a workshop where the schematic, the copper and the software are treated as one object. Read the full controls engineering services page to see the six disciplines we run day to day.
Every engagement below is delivered as an integrated package, not as a loose collection of trades. We keep our own panel shop, our own firmware bench and our own commissioning kit, so the person who draws the loop is often the person who proves the loop. Each service links through to the full description on the services page.
We strip, re-rail and rewire obsolete control cabinets so they meet current thermal and fault-current expectations. A controls survey precedes every strip-out, and a full wiring schedule leaves the workshop with the panel.
Control Panel Upgrades →Logic, tags, alarms and operator screens are written and version controlled as a single deliverable. We unify fragmented PLC families behind one SCADA layer so operators stop juggling three different terminals.
PLC and SCADA Integration →Industrial Ethernet, managed switching and segmented traffic give the plant a network that behaves like infrastructure instead of an accident. We document addressing, converge properly and hand over a live topology map.
Factory Floor Networking →Where original drawings have vanished, we reverse engineer the machine from the copper outward and rebuild it as a supported system. Downtime windows are planned around production, not around convenience.
Legacy System Refits →From thermocouple to flow meter, every loop is calibrated, documented and tested against its datasheet. We tune the loop, then we prove it holds under real process load before sign-off.
Sensor and Instrumentation Loops →Planned inspection, spares holding and rapid response keep the plant running between capital projects. Contract customers get priority scheduling and a named controls engineer who already knows the machinery.
Maintenance Contracts →EXP CONSTRUCTION LTD opens its autumn panel-refit window for manufacturers who want their control estate inspected, documented and modernised before the busy winter production schedule begins.
Computer integrated systems design is often described as if it were a purchase rather than a discipline. EXP CONSTRUCTION LTD treats it as a discipline. A panel is not a box of terminals; it is the first physical expression of an architecture that has to survive heat, vibration, dust, operator error and time. When the architecture is decided early, the cabinet simply follows. When it is ignored, every downstream task becomes an argument with the wiring.
That is why the work begins with a walk of the plant and an honest assessment of what the existing installation can still carry. We photograph, tag and measure, then we build a model of the machine as it truly is, faults included. Only after that model exists do we propose the refit. It is slower for the first week and dramatically faster afterwards, because the installation team never has to guess what a concealed core actually does.
The practice spans six closely related disciplines. Control Panel Upgrades deal with the physical cabinet and its protection. PLC and SCADA Integration deal with the logic and the operator interface. Factory Floor Networking deals with the transport layer that carries data between cells. Legacy System Refits deal with the machines that predate all of the above. Sensor and Instrumentation Loops deal with the measurements that everything else depends upon. Maintenance Contracts deal with keeping all of it alive long after the commissioning van has left.
Because these six areas share one bench, problems surface differently. A nuisance trip that a panel-only contractor would patch at the relay is more likely, in our hands, to be traced to a scaling error in the analogue input that feeds the logic. A network storm is investigated alongside the drive firmware that generated it. A legacy machine is refitted with the knowledge that its replacement sensor loop must speak the same protocol as the new SCADA server. Integration is not a slogan here; it is the reason the disciplines sit next to each other.
The workshop at 18 Hollyhurst Road in Sutton Coldfield is deliberately sized to build panels and prove software under the same roof. Engineers can flash a controller, wire it to a physical mock-up and watch a loop respond before it ever reaches the customer site. That rehearsal culture is the single biggest factor in short commissioning windows. A fault found on the bench costs minutes; the same fault found on a live line at three in the morning costs production.
Across the Professional, Scientific, and Technical Services sector, clients increasingly need suppliers who can hold both the drawing and the debugger. Accounting practices want their site data logged. Engineering houses want their pilot lines instrumented. Property portfolios want their plant rooms monitored. All of these needs point to the same underlying capability: the ability to design an integrated system and then stand behind it in the field. That is the capability EXP CONSTRUCTION LTD exists to provide.
A full site walk captures existing panels, cabling, protocols and operator habits. Findings are written up as a condition report before any price is discussed.
Loop drawings, network schedules and panel layouts are produced as a matched set. The client sees the system on paper before a single core is pulled.
Panels are assembled and controllers are programmed in the workshop. Hardware and software are proven together against a mock-up of the process.
Installation happens inside agreed production windows. Loops are calibrated, networks are certified and the SCADA layer is handed over live.
A maintenance contract covers inspection, spares and response. Documentation is kept current so the next engineer inherits knowledge, not mystery.