Elhance was appointed to carry out fire risk remediation works to a prominent town centre building, located in a shopping mall and directly adjoining a hotel. The building sits in a busy environment with significant footfall, which added an extra layer of complexity to the project.
The existing façade contained several combustible components, including insulation and timber elements such as plywood and battens. These materials had been installed behind a zinc façade system, which requires a flat and consistent surface to achieve an acceptable finish, particularly above the soffit panels.
To safely deliver the works, the building was fully scaffolded to roof level, approximately 18 metres high, across nine scaffold lifts. Our scope involved the careful removal of all combustible materials back to the cement particle board substrate. We then installed a new compliant façade system comprising top hats, Rockwool Rocslab insulation, fire breaks, and Rocbar products, which together provided a flat and stable surface for the new Vieo façade system supplied by Euroclad.
We also included soffit works as part of the project. These comprised the installation of new top hats, non-combustible insulation, and Opus plank soffit panels. These were selected to match the colour and appearance of the new Vieo cladding, and maintain a consistent architectural finish.
The overall design intent was prepared by the Employer’s architects, who also managed engagement with the local planning authority. We followed this approved design, with one minor variation required during the project.
Due to material availability and lead times, the specified cladding finish was changed from Sirius matt to Sirius standard. This adjustment was agreed with the project team, and did not affect performance or appearance.
The new wall build up achieved a thermal performance of 0.24 W/m²K. To reach this standard, the depth of the external wall had to be increased. At soffit level, the thermal performance was significantly improved, as the original construction contained no insulation at all.
Before installing the new gridwork, we engaged our fixings supplier to carry out pull out tests on the existing concrete substrate. The results of these tests allowed our structural engineer to specify the correct concrete anchors, ensuring that the new system was safely and securely fixed.
Wind load calculations were completed by Euroclad, as the façade system supplier, and these determined the fixing centres for the top hats. The fire break system, supplied by Siderise, was designed to provide 60 minutes insulation and integrity. This included horizontal fire breaks at slab levels and vertical fire breaks at compartment walls, forming a robust and compliant fire stopping strategy.
Throughout the design and delivery stages, we worked closely with Building Control, provided through an approved inspector, to ensure full compliance with Building Regulations.
The location of the building presented several logistical challenges. The scaffolding had to bridge exits from both a multi-storey car park and a busy delivery yard, while also extending over a public footpath. Managing pedestrian safety was a critical consideration, and the scaffold design and site management arrangements were developed to ensure safe access routes at all times.
Transport and traffic management were equally important. The building sits on a roundabout, meaning deliveries had to be carefully planned and timed to minimise disruption and maintain safety for road users.
During the removal of the combustible façade components, we identified that the faces of the concrete floor slabs were not level. The previous installer had relied on timber battens to achieve line and level, introducing further combustible material into the façade build up.
To resolve this, we designed a new subframe solution using adjustable Z-rails and top hats. This allowed us to accurately achieve line and level across the elevation, while fully removing timber from the construction.
Quality assurance was central to our approach. Our Site Quality Management Plan set out clear processes to confirm that all combustible materials were removed and that replacement components were installed correctly. This included construction issue drawings, supporting calculations, and technical literature for all elements of the works.
We implemented defined inspection stages and hold points, supported by statistically determined sampling and detailed progress photography. Agreed programmes were followed for imagery capture, quality reporting, and information upload to our project database.
At completion, final sign off confirmed that all quality records and technical information had been passed to the Elhance team responsible for producing the Operations and Maintenance manual, which was issued to the Employer at Practical Completion.
This project highlights Elhance’s ability to deliver fire risk remediation works in complex, high-footfall town centre environments. By combining careful planning, robust engineering, and strong quality control, we delivered a compliant façade solution that significantly improved fire safety, enhanced thermal performance, and respected the operational demands of a busy mixed-use location.