EMERGENCY STRUCTURAL REPAIRS AND REPLACEMENT
TO 7,500SQM INDUSTRIAL BUILDING
Red Leaf Enviro were contacted by enVar to investigate, shore up and repair their main building after it was damaged by heavy plant, resulting in a shut down of the facility
CLIENT
enVar’s flagship site in Cambridgeshire, the UK’s largest in-vessel and windrow composting facility, processing over 100,000 tons per year
PROJECT
Emergency repair and shoring up of damaged building, leading to a long term repair and replacement
48
Hours
TO SHORE UP
1,200
SQM
ROOF CLADDING
14
DAYS
TO FULL REPAIR
When heavy moving plant collided with and damaged two main structural supports at enVar’s 7,500sqm building, the health and safety implications led to the immediate and full shut down of the site. The plant collided with the supports forcefully enough to unseat them from their vertical position to a visible diagonal, suggesting they were offering absolutely no support to the roof structure above. This could have resulted in the collapse of the roof section and further damage to the facility.
The financial implications for a prolonged site shut down meant that an effective temporary structural solution needed to be found rapidly to allow the site to continue operations, safely. enVar contacted Red Leaf Enviro to provide an emergency repair solution that would allow the site to reopen as soon as possible. Within 48 hours of the structural damage, Red Leaf Enviro were on site with an emergency repair strategy to safely shore up the roof structure and damaged beams.
The Red Leaf Enviro strategy involved using a number of shipping containers along with specially fabricated steel props and braces to support the main rafter structure of the roof and to ensure the damaged beams presented no fall hazard. This temporary fix would make the area safe for work to resume while replacement beams were fabricated and the old beams dismantled. The HSE approved the emergency work and the site was able to open again while work on dismantling the damaged beams took place.
A 250t crane and a selection of other specialist lifting equipment and techniques were deployed to disassemble the damaged sections. This included a number of 20t concrete rafters, which had to be disassembled and then lifted down around 12m and removed from site.
Red Leaf Enviro designed and fabricated the steelwork required for the temporary shoring up of the building, along with fabricating all necessary replacement structural parts for the repair. All materials were delivered to site ready for assembly. Limiting disruption was a high priority for enVar and so main lifting work was carried out over weekends, when the site was inactive, this meant the complete roof install was finished 14 days from the initial damage occurring. This allowed material processing and other site operations to resume at a normal level, minimising impact on the business.
Red Leaf Enviro designed and fabricated the steelwork required for the temporary shoring up of the building, along with fabricating all necessary replacement structural parts for the repair. All materials were delivered to site ready for assembly. Limiting disruption was a high priority for enVar and so main lifting work was carried out over weekends, when the site was inactive, this meant the complete roof install was finished 14 days from the initial damage occurring.
“I WANT TO THANK THE RED LEAF GROUP TEAM. OUR PROJECT AT ENVAR BECAME PROBLEMATIC AND STOPPED A MAIN ARTERY OF OUR BUSINESS. RED LEAF GROUP COMPLETED THE HIGH-RISK TASK QUICKLY AND EFFECTIVELY, MEANING ENVAR COULD CONTINUE TO WORK AS A PROFITABLE BUSINESS.”
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