A leading global food manufacturer, significant issues at a key UK factory, involving the presence of HSE condemned materials; A Reinforced Autoclaved Aerated Concrete (RAAC) plank roof, with a high potential to fail and collapse into the factory. A risk to life and the future of the business.
The ceilings were suspended on hangars fixed through the RAAC planks. Asbestos was also discovered. AB developed an innovative solution to remediate the RAAC roof, which included the full replacement of factory ceiling panels and working 24/7 to restore health, safety and BRC compliance which then, facilitated the site’s return to production.
Safety Compliance: Remediate life-safety hazards to make the building safe for occupants and production to safely continue.
Hygiene Improvement: Replace the existing factory ceilings and undertake BRC audit remedial works to meet stringent hygiene standards.
Asbestos & RAAC Remediation: Remove asbestos and reinforce any RAAC planks to ensure negligible structural integrity risks prevail.
Structural Integrity: Implement necessary steel works to support the RAAC, the new factory ceiling structure and associated building services.
Operational Efficiency: Staged a safe phased return to production and continued remediation works safely within a ‘live factory environment’
Assessment and Planning:
• Conduct a thorough survey of the existing ceiling structures, focusing on RAAC elements, asbestos, services and food safe factory ceiling panels.
• Developed a detailed project plan outlining the steps for RAAC remediation, ceiling removal, and new installation.
• Managed all CDM & HSE duties
Steel Works:
•Managed the CDM design and installed additional steel supports to mitigate RAAC collapse
• Dispose of old materials in a safe an environmentally compliant manner.
Ceiling Removal:
• Design and install additional supports to prevent collapse of the RAAC panels and support the new ceiling
• Ensure all steel works comply with best practice, industry standards and safety regulations.
Installation:
• Install the new food safe ceiling panels
• Integrate appropriate lighting and ventilation systems.
• Conduct rigorous inspections to ensure the factory envelope meets all specified insurance and BRC requirements.
The success of this very sensitive and dangerous project demonstrates Ambrey Baker’s commitment to delivering safe, innovative, high-Quality construction solutions tailored to the specific needs of manufacturers and the food production industry.
Our meticulous HSE & CDM regimes, planning, execution and quality assurance processes ensure that our clients receive the best possible outcomes, safeguarding and enhancing their operational facilities and capabilities
RESOLVE COMPLEX INDUSTRIAL DESIGN OR CONSTRUCTION CHALLENGES WITH CONFIDENCE.
For a no obligation initial consultation with one of the UK’s leading industrial construction and technical advisory experts, contact us today to gain clear, practical guidance on critical technical, engineering, and construction issues.
Paul Waldeck BEng(Hons), CEng., MICE., MIStruct.E, MIMech.E., MASHRAE,
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