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PROJECT PROFILE

Food Production Factory Multi Trades Roofing Project

INTRODUCTION

In the UK, food production facilities often feature pitched metal roofs, a design choice that is both practical and economical. The pitched design allows for efficient water drainage, crucial in the UK’s variable weather conditions, while the metal construction offers durability and low maintenance. Accommodating various types of food production activities, from processing raw ingredients to packaging finished products, these buildings are typically insulated systems, ensuring that the internal environment remains safe and conducive to food production, storage, and distribution. These plants often incorporate rooftop M&E equipment, including extraction units, to help adhere to stringent hygiene and safety standards.

UK FOOD PRODUCTION

Food and Drink Sector Experience Secures Project

Throughout the UK, Starfish Construction completes many high-quality projects within the food and drink sector. Our reputation, strong relationships with surveyors and project engineering managers, and our Diagnose, Design and Deliver process positioned us well in this client’s competitive tender process.

Initially, our client requested that we support them in diagnosing and designing a solution to eliminate condensation within their industrial roofing system. Our technical surveying division visited the site and removed sections of the existing built-up metal roof to determine the cause of condensation formation. Our in-house design team reviewed the condensation risk analysis (CRA) calculations based on the gathered data and proposed a solution to eliminate condensation within the roof space.

We also assessed the Mechanical and Electrical (M&E) plant across the roof as part of our designed solution. The Mechanical equipment consisted of large extraction pipes running across the roof pitches. The electrical equipment was predominantly cable trays laid directly onto the roof.

DURATION

18 Months

ROOF + M&E REPLACEMENT

4500 m2

AN ENGINEERED SOLUTION FOR A LEAKING FOOD PRODUCTION ROOF

As part of the remediation, we increased roof depth and added thicker insulation to improve U-values and temperature control. We had to alter and raise the M&E equipment due to its age, replacing the existing ductwork. A Big Foot Support System was installed to distribute weight on the new roof evenly. The project involved removing the old roof components, including the sheet, insulation, and purlins, and installing a new, durable roof.

We sealed the roof liner with EPDM tape to create a Vapour Control Layer, then installed a deeper bar and bracket system for the high-performance insulation, finishing with a 0.7mm Plastisol-coated metal sheet. The upgrade also included new gutter systems with reinforced membranes. Starfish Construction, as Principal Contractor, managed the design and installation.

roof icon
food production plant roof replacement

Group Expertise

CONTINUITY AND PROCESS MANAGEMENT

Over several years, Starfish Construction has expanded its divisions and service offerings to meet the needs of its clients. This expansion was a key priority to ensure that as principal contractor on many projects, we can manage and control all aspects, including trained personnel, work schedule and especially site safety. Starfish Access Services (SAS) was responsible for the project’s scaffolding and roof edge protection.

Our clients, including local authorities, utility providers, the defence industry, and other organisations across the UK, regard our National Access and Scaffolding Confederation (NASC) membership as a mark of quality, safety, and professionalism. Consequently, many clients specify that the scaffolding provider for their projects must be a member of the NASC.

Starfish Construction Group also completed all the Mechanical and Electrical works for the client, adding a genuine multi-trade dimension to the project.

FULLY OPERATIONAL FOOD PRODUCTION FACTORY

Limited movement around the site created logistical challenges for the project. As HGVs entered and left daily, our traffic management process needed to be robust. The factory remained fully operational throughout the work, and the packaging line below our area of work, which included a crisp production conveyor belt heading for the packaging area, had to remain dry to maintain product quality.

Our sequence of works was carefully planned, involving the removal of 1m-wide sections of roof sheets from ridge to valley, followed by reinstating the new system before proceeding to the next section.

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    Our project team outlined our proposed solution to the client and their engineers, and together, we determined that this was the best approach to reduce the risk of water ingress drastically. This approach demonstrates Starfish Construction’s flexibility as a main contractor, supporting the client and designing solutions that provide peace of mind and confidence. We are growing our reputation as the contractor of choice for commercial roofing projects in high-risk food and beverage environments, particularly when working above a live food production facility.

    The project was highly praised, and the roof upgrade system we designed and installed has been very successful. We created an effective solution delivered to the highest safety standards for which our client highlighted these key facts in our post-project appraisal.

    The client said: ‘Your site manager went out of his way to engage proactively with our team daily and kept us informed of everything relevant throughout the project delivery process. We found this reassuring and very encouraging from our perspective.’

    PROJECT CHALLENGES AND SOLUTIONS

    Effective and Qualified Site Team and Project Managers

    Starfish Construction Group's ongoing investment in experienced site managers proved to be a significant advantage, particularly in addressing client concerns related to permit writing processes. By ensuring our site managers had the necessary permit training certificates, we were able to quickly alleviate these worries and demonstrate our capabilities.

    Our on-site teams efficiently implemented and monitored permits, showcasing a proactive approach that reassured the client. This commitment to procedural excellence extended to all aspects of the project. Starfish Construction consistently achieved clear audits by strictly adhering to the client's robust monitoring standards for Quality, Health & Safety, and operational procedures throughout the entire project duration.

    Our success

    PASSING CLIENT INSPECTIONS WITH FLYING COLOURS

    During one of the client's Permit to Work audits conducted by a UK Projects Health & Safety Specialist, the feedback was excellent, with some particular areas highlighted as being above average. The Auditors' comments are as follows:

    "Today, I completed a PTW audit covering the Starfish Construction-controlled Roof Refurb project permits from June 15th to July 19th. For these third-party PTW audits, I normally expect the average score to be greater than 95%. The average score across the ten permits audited Today was 100%, which is fantastic to see and is an increase of 3.2% from my last audit in June, which was already above the average."

    This extremely high-marking audit is a testament to our HSQE policies and processes, as well as the diligence of our project managers and supervisors.

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    KEY STRENGTHS AND SUCCESSES

    Below is an extract from the client’s Project Health & Safety Specialist report.

    The Starfish construction site manager was a standout throughout the project; his management style, along with his respect for the contractors, resulted in a working partnership that was very impressive. Your Cloud-based construction project management system is excellent. It provides clear visibility of quality audits, Health & Safety inspections, incidents, near misses, and a wide selection of photographs at all project stages. We asked the client if they would like to work with Starfish Construction again. We were delighted to receive a firm ‘Yes’.

    INDUSTRIAL ROOFING

    WATERTIGHT ROOF

    MECHANICAL & ELECTRICAL

    TECHNICAL SURVEYING

    We were proud to collaborate with this major food production client on a truly multi-trade refurbishment. The project posed unique logistical challenges, requiring our team to work with precision whilst the factory remained fully operational.

    By carefully removing and reattaching small sections of the roof, we effectively reduced the risk of water ingress and maintained production continuity. Our in-house capabilities, from Starfish Access Services to our M&E team, played a vital role in delivering a seamless and comprehensive solution.

    This integrated approach, combined with our strict adherence to the client's health and safety standards, ensured a smooth and efficient project delivery. The successful completion, along with the client's praise for our site management, proactive communication, and clear audits, is a testament to our team's expertise and dedication. We look forward to the opportunity to work with them again in the future.

    SHAUN McCLUSKEY, OPERATIONS DIRECTOR