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PROJECT PROFILE

Whisky Bonded Warehouse Licensed Asbestos Removal

INTRODUCTION

Our client is a grain whisky producer based in Scotland. They distil and mature grain whisky used in the production of world-renowned whiskies. Our combined turnkey divisions have completed on-site roof replacements for several warehouses. Starfish Environmental & Asbestos Services (SEAS) were part of these projects to remove the existing Asbestos insulation boards (AIB) from the site. AIB is a Group One carcinogen, as recognised by the World Health Organisation, known to cause cancer.

ASBESTOS INSULATION BOARD

A safe and licensed approach to Asbestos Management

The AIB was installed historically on site, and its condition was in the early stages of degradation. The AIB, outlawed in the U.K. in 1985, presented a severe risk of contaminating the valuable stock below. As part of the client’s ongoing asbestos management planning, they utilised a priority assessment algorithm to identify asbestos-containing materials for abatement works.

The client invited SEAS to tender with other contractors, and we successfully won the contract. SEAS managed every aspect of the AIB removal and disposal from a potentially hazardous environment. Asbestos-related diseases cause around 5000 deaths per year in the U.K. Working with asbestos requires a high degree of regulatory control. The purpose of HSE licensing is to achieve this. To obtain an asbestos licence, contractors must demonstrate the necessary skills, competency, expertise, knowledge, and experience in working with asbestos, as well as an excellent health and safety management system.

DURATION

20 weeks

Dangerous Environment

ATEX-Rated Zone

REMOVING AIB FROM AN ATEX AND COMAH AREA

The project is a bonded warehouse designed to store and mature grain whisky, featuring a built-in racking system for storing the whisky barrels. “The storage of high volumes of barrels of maturing scotch whisky presents serious explosion risks,” says Jamie Purdon of SEAS. Jamie continued, “Some whisky in every barrel evaporates through the oak during the ageing process–known as the ‘Angels’ Share’. The maturation process and ageing period depend on the individual whisky, and the barrels can be stored for over 20 years, each representing a significant investment for the distiller. Due to the volume of high-strength spirit, this site is classed as a top-tier COMAH and ATEX Zone 2 hazardous area.

Aged whisky from reputed distilleries commands high prices and retains value even during recessions and inflationary periods. In fact, over the last decade, whisky has proved to be a better investment than cars, first-growth Bordeaux or collectable watches. Starfish Access Services Ltd constructed a working platform over the whisky barrel racking system to protect the valuable stock below and to provide a working platform to carry out the licensed asbestos removal works.

SEAS setting up for licensed asbestos removal

SEAS AIB removal

HSE LICENSED ASBESTOS MANAGEMENT

The warehouse survey identified the areas under the roof that required AIB removal, with the working area and storage zone split into cells; the client decided that four of these would fall under the project area. ATEX stands for “ATmosphères EXplosibles,” a European directive that sets the standards for equipment and protective systems intended for use in potentially explosive atmospheres.

ATEX Zone is a classification system that identifies areas with a risk of explosion due to flammable gases, vapours, dusts, or powders. In this instance, ATEX Zone 2 vapours are associated with the high alcohol content of the whisky storage. The ATEX Directive classifies equipment that can be used safely within these zones. SEAS had to resource intrinsically safe plant & equipment to mitigate the risks associated with an ATEX environment. Ongoing controls, including gas monitoring, air management processes, permitted systems, and intrinsically safe equipment, were the baseline for a safe system of work. Compliance with ATEX standards ensures that the equipment meets specific safety requirements, reducing the risk of ignition and explosion in potentially explosive atmospheres.

Employers must classify areas where hazardous explosive atmospheres may occur into zones. The classification assigned to a particular zone, as well as its size and location, depends on the likelihood of an explosive atmosphere occurring and its persistence if it does.

SAFE AND PRACTICAL AIB REMOVAL SOLUTIONS

  • SEAS completed the removal of Asbestos Insulating Boards (AIB)
  • Project involved a bonded warehouse storing grain whisky in an ATEX-rated Zone
  • SEAS managed all aspects of AIB removal and disposal, ensuring compliance
  • The work was conducted in a fully operational warehouse and removal of
  • A fully sealed, licensed enclosure with extraction units created a significantly safer working area for site workers and warehouse employees, enhancing the AIB removal area.

    Erecting the scaffold working platform over an intricate racking system designed for the whisky barrel casks posed a significant challenge for Starfish Access Services Ltd., requiring careful planning and precision.

    Setup and removal of AIB

    SUCCESSFUL AIB REMOVAL AND PROJECT OUTCOME

    The scaffold platform was designed to facilitate working access, emergency egress, and hoisted mechanisms for lifting and lowering plant and equipment, including the removal of hazardous asbestos waste. The fully boarded work platform is constructed above the rack and tier cask storage, with lightweight working platforms erected beneath the roof to provide a safe working area for licensed asbestos removal activities.

    Once the scaffolding erection was complete, SEAS undertook enclosure construction to provide critical control over the prevention of dust associated with the removal works. The enclosure was constructed from heavy-duty impact protection correx, 1000-gauge polythene, heavy-duty PCL tape, spray glue and staples fixed to a timber frame for enclosure support. The roof structure was pre-cleaned and sheeted out of the removal area.

    We installed an airlock system to enable safe decontamination procedures for the removal team and an oversized enclosure to accommodate the large parcels involved in an intact removal. SEAS also installed three intrinsically safe extraction units to create negative pressure within the removal areas and to manage air inside the enclosure. Additionally, we set up a series of vision panels to facilitate observation and supervision from outside the removal zone.

    bonded warehouse asbestos removal from roof

    HIGHLY SKILLED AND LICENSED ASBESTOS MANAGEMENT IN AN ATEX ZONE

    The client-appointed analytical contractor conducted comprehensive air monitoring throughout and after the project to ensure the safety of the site team and occupants. Removing the category one carcinogen from the site has significantly updated the site’s asbestos register and brought it closer to becoming asbestos-free. More immediately, it allowed for the installation of various new modern services and ATEX management systems into the Bonded Warehouse, which previously could not be installed due to the condition and location of the AIB.

    BUILDING ENVELOPE

    ROOFING

    LICENSED ASBESTOS MANAGEMENT

    TECHNICAL SURVEYING

    I'm immensely proud of our team's achievement on this project. Handling asbestos in an environment with significant explosion risks, such as a whisky bonded warehouse, required an exceptional level of precision and expertise.

    Our work here showcases SEAS's commitment to not only meeting but exceeding the highest safety standards. We successfully navigated the complexities of an ATEX-rated zone, sourcing intrinsically safe equipment and implementing rigorous monitoring to ensure a completely safe removal process.

    This project is a perfect example of how SEAS reaffirms its position as a trusted and expert partner in licensed asbestos management, delivering excellence even in the most challenging and sensitive of environments.

    JAMIE PURDON, ASBESTOS DIRECTOR AT SEAS