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Cereal Partners UK
Design & Build . Refurbishment & Fit-out . Factories
Cereal Partners is an international joint venture between General Mills and Nestlé, with the sole purpose of producing some of the most well-known cereal brands. This particular project was phase 2 of a part factory refurbishment project, following the transformation of their internal welfare facilities. Phase 2 required design and specification for a roof covering to replace the existing EPDM roof which spanned 6,400m2. The existing roof was installed in 1993 and was, unfortunately, failing in several areas. To ensure that safety was a top priority, we installed a total of 500 linear meters of scaffolding with heights varying from 5 – 14 meters over the course of this project.
Challenges and Solutions
Before we even started, our priority was to ensure we produced the highest quality roof that would see them through another 25+ years. After thorough market research, we invited three different manufacturers to pitch for the opportunity to help us create an appropriate bespoke system. After interviews, presentations and much consideration, we decided to go with the company Bauder. The Bauder specification was a high performance elastomeric felt roofing system which is underwritten by Bauder and guaranteed for 25 years.
The biggest challenge we faced, was that the roof itself covers a major production facility, which was to be fully operational throughout the project. As such, we had to come up with a construction method that did not affect the operations and kept disruption to an absolute minimum. To begin, we engaged Bauder to carry out a non-invasive moisture mapping survey of the roof. The results then gave us an appreciation of the extent of water penetration into the fabric of the roof, enabling us to target which areas required a full strip out and which areas could be overlaid. The instrument used was a Troxler 3216 roof reader, which utilises the thermalisation of neutrons to measure moisture concentration within a roof structure.
Following on from the results of the survey we were able to look closely at the parts of the roof structure that required a full strip off and design an internal scaffold within the production area to protect the manufacturing process.
Unfortunately, the timescales for this project were greatly impacted by the coronavirus pandemic. Originally we had intended to increase the labour on-site by introducing more roofing gangs on a planned basis. However, on the 17th March, we concluded with our client that we should keep the number of workers in the space to a minimum, to ensure welfare facilities weren’t overstretched and the appropriate safety measures could be adhered to. A week later as the first national shutdown was introduced, all work was temporarily suspended. Work recommenced in mid-June, with a restricted number of contractors on site. Despite the delay in completion, the project was completed within budget and our client was very happy with our conduct on-site and the resulting new roof.
“The project was well controlled, with all contractors involved collaborating well together, creating an excellent end product which will provide long term protection to a vital production area for one of the country’s main breakfast products.”