Kara Foods

Project details

Our Projects - Kara Foods

Eccles, Manchester

Structural repairs

18 weeks

BPG Scope of Works:

  • Replacing a specially designed concrete sub base
  • Insulating the floor with panels and heater mats
  • Installing rubber mats under the stainless steel frame
  • Placing heating wires to reduce the risk of temperature transfer into the concrete sub base
  • M&E installations
  • Bespoke fibreglass resin surface membrane
  • Crash decks to withstand the impact of falling ice

The challenge

Kara Foods is a major supplier to the food retail industry. One of their 6-tonne freezer units had experienced considerable frost damage to the floor. In fact, the whole unit was leaning badly because of the failure of its structural supports. Containing goods for some key food chains, shutting down the freezer was not an option. The challenge was to conduct these major structural repairs in a live environment and losing no stock or business.

The solution

Building Projects Group worked closely with a structural engineer throughout the whole project to ensure the design could cope with temperatures of -30°C and below, as well as a weekly thaw and wash down. The use of temporary screens and sealed partitions allowed building works to continue in the live environment to prevent contamination and downtime.

The benefits

The project was completed to schedule and to the exacting standards of the client. There was absolutely no unscheduled downtime or loss of business, which was critical. It meant a considerable amount of work had to be undertaken in very difficult working conditions, which required strategic planning and preparation. But, in the end, the freezer unit was repaired and restored, and was much better suited to handle its workload in the future.