RAAC Remediation at Live Food Production Facility

PROJECT PROFILE

RAAC Roof Replacement in a Live Food Production Facility

INTRODUCTION

When the client and their agent identified structural risks associated with RAAC (Reinforced Autoclaved Aerated Concrete) in a 40-year-old food production facility in Leith, Edinburgh, they required a contractor capable of addressing a complex, high-risk project while maintaining operational continuity and compliance. Based on past successful work and specialist experience in RAAC remediation, Starfish Construction was appointed to lead the design, planning, and delivery of the solution.

UNDERSTANDING THE CHALLENGE

Safely Replacing RAAC While Keeping Food Operations Running

The building is a high-specification food production facility that prepares meals for prestigious catering events across the UK. With residential buildings on three sides, a food-safe internal environment, and live operations throughout the programme, the project presented significant constraints.

A structural engineer commissioned by the client identified RAAC panels in one section of the flat roof and recommended urgent remedial action. After a successful tender submission, we were appointed to manage the project to:

Complete a survey to evaluate the outline scope of works
Provide a knowledge-backed remedial proposal
Develop a strategy to complete the RAAC removal without impacting production.

DURATION

20 weeks

CLIENT PROJECT SCORE

10/10

Our Expertise

DIAGNOSTIC & DESIGN APPROACH

Given the food-safe and operational nature of the facility, we undertook a highly detailed diagnostic process before works began:

Mechanical, Electrical, and Refrigeration Survey
Completed a full assessment of internal services, mapping all interfaces and required isolations to develop a method of work that kept kitchen operations live throughout the project
RAAC Core Sampling. Understanding the composition of the panels through core sampling is essential to safely and efficiently deliver RAAC removal projects
We carried out intrusive surveys of the RAAC panels to determine material density and identify any screed overlays, enabling accurate removal-timeline planning and cost estimation
Our experience shows that varying RAAC densities can significantly affect removal methods and safety controls.

SAFE RAAC REMEDIATION IN A LIVE ENVIRONMENT

The RAAC-affected area was located directly above critical infrastructure, including a walk-in fridge, freezer and dry goods storage. To protect these facilities and maintain food safety, our NASC-approved Scaffolding Division erected a fully weatherproof temporary roof to safeguard the building interior from wind and rain. An internal crash deck system was also installed to protect the operational areas while providing safe, walkable access for the RAAC removal works. Service isolation and reconnection across the M&E and refrigeration systems were carefully planned and delivered without interruption. Through detailed sequencing, adjacent kitchen areas remained fully operational throughout the works, with no disruption to food production.

INTEGRATED SERVICES AND DIVISIONS

Complete In-House Project Delivery Model

Operating as Principal Contractor, we delivered all elements of the project using our multi-disciplinary in-house teams, ensuring complete control over programme, quality, and compliance.

Roofing and Design

Our in-house Design team managed every aspect of the new flat roof installation, developing fully compliant specifications aligned with the client’s requirements, coordinating structural assessments and supplier engagement, and working closely with the site team to resolve technical challenges without delaying the programme.

M&E and Service Integration

We also managed all service isolations and reconnections in-house, ensuring critical refrigeration and power systems remained protected throughout the works and were reinstated in line with operational and production requirements.

Environmental Oversight

Our SEAS division provided comprehensive environmental and asbestos monitoring through:

Regular air quality inspections and compliance checks
Integrated risk management to maintain safety and environmental standards
Early identification and resolution of potential delays.

By integrating SEAS into the project team, we maintained a proactive approach to safety and regulatory compliance throughout.

Our success

PROJECT OUTCOME AND VALUE DELIVERED

The project was completed with zero disruption to food production operations, supported by an accurate RAAC diagnosis and a clearly costed removal plan. High-risk works were safely sequenced within the live facility, with close collaboration across scaffolding, roofing, M&E, design and environmental management. By delivering the works entirely through our in-house divisions, we maintained greater control, consistency and compliance throughout every stage of the project.

food production facility RAAC remediation

We are extremely pleased with the delivery of our RAAC removal and flat roof replacement project by Starfish Construction. The Project Manager and his team demonstrated exceptional professionalism, clear communication, and attention to detail throughout the project. We particularly appreciated the seamless integration of Starfish Construction’s in-house design team and environmental division, which ensured that all compliance, health, safety, and quality requirements were consistently met.

Challenges were managed proactively and transparently, ensuring minimal disruption to our operations.

The project has been delivered to a standard that fully meets and even exceeds our expectations. We are delighted to award Starfish Construction a score of 10 out of 10 across all areas of delivery.

CLIENT TESTIMONIAL

Explore the RAAC Knowledge Centre

Access practical guidance, expert insight, Duty Holder resources and completed project experience covering RAAC identification, assessment, management and remediation. The Starfish Construction RAAC Knowledge Centre brings together the information building owners, estates teams, surveyors, consultants and project stakeholders need to understand the issue, consider the available options and identify the appropriate next step.

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