Our client is the UK’s leading pub, cider and beer company and the name behind a host of well-known beer and cider brands, which accounts for around 30% of the nation’s apples for their ciders. More than 90% of their beers brewed in production plants across the UK sell within the UK.
Starfish Construction has supported the client with several completed works at Hereford, including asbestos removal and the refurbishment of the CO2 recovery unit building. These successful projects have provided the client with confidence in our ability to deliver this higher-risk project.
Using our Diagnose, Design and Deliver approach, Starfish Construction carried out a drone survey, which allowed examination of areas previously unreachable due to the fragility of the asbestos roof. This approach enabled the project to be designed and accurately priced before the works started providing stakeholders with cost certainty.
This project involved removing an asbestos roof above an operational Canning Line and installing a new composite clad roof system and upgraded gutters. We also designed and upgraded the internal lighting to ensure the light conditions were in line with relevant lux requirements for this area.
To ensure no water ingress or contamination to the Canning Line below, we installed a fully sealed working platform above the factory area. We also incorporated a temporary drainage system in the unlikely event of water ingress during the works.
- 2000m2 of asbestos cement roof stripped and new composite cladding installed
- Fully operational production line continued throughout project works
- High level of liaison between Starfish Construction and the client throughout the project
- Completed on time and to agreed budget
- Drone survey enabled a complete diagnosis of the failed roof and allowed the best solution
Challenges and Solutions
A high level of detailed planning is required when working in a live food & drink environment. Ensuring production continued uninterrupted was paramount, as the Canning Line is a fundamental part of the brewing production process. Meeting the client’s expectations required a multi-faceted management approach from HSQE to Commercial Managers. Starfish Construction excels at high-risk and high-profile projects, continually demonstrating our teamwork and collaborative approach. We regularly design out challenges using our knowledge and expertise.
Our site manager and stakeholder representative worked closely to coordinate the scope of works. Daily and weekly update reports highlighting all project activity, including project progress reviews with photographs, the percentage breakdown of the works completed, project KPIs and any other business created honest and open communication channels between the client and us.
The Canning Line is the first building you see when you approach the site, with all visitors reporting to this location. The structure now reflects the company’s reputation for providing high-quality products.
The completed re-roofing project is now fit for its purpose, offering a fresh, clean look. The white internal liner to the underside of the roof is now watertight, ensuring a suitable and safe environment for production in the future unhampered by a poorly performing roof.
This project allowed an in-depth collaboration between Starfish Construction’s Projects and Design divisions, ensuring delivery of each phase seamlessly. Without a doubt, this project came with its difficulties. However, our internal communication and problem-solving abilities assured us that the client didn’t experience any productivity downtime or surprises.
This project was a real testament to our ever-evolving capabilities as a high-performing contractor, and we look forward to the next challenge.
Kevin McCormack, Associate Director, Starfish Construction