Alkegen Rainford - Roofing and Refurbishment Project

The solution

– Frank Rogers led the programme as Principal Contractor, managing multiple specialist subcontractors under stringent CDM regulations.

• Access & safety – Full scaffolding erected with fall-arrest safety netting, debris netting, and crash decking systems installed beneath live working areas to protect both workforce and operations.
• Roofing works – Installation of a high-performance overlay roofing system designed to encapsulate asbestos cement sheets without removal, achieving a U-value of 0.18 W/m²K. Scope included removal and replacement of rooflights with Filon Supasafe DR units, lining of rainwater gutters, reinstatement of downpipes, and installation of parapet wall cladding and cappings.
• Cladding upgrades – Internal wall and roof cladding replaced or over-clad to address condensation, improve insulation, and create a cleaner, more resilient production environment.
• Programme management – Works phased around wet plant shutdowns and production schedules, with critical path sequencing to maintain operations. Weekly site reports confirmed progress remained on programme despite periods of adverse weather.
• Health & safety – A pre-construction asbestos demolition and refurbishment survey was undertaken. Site operations included rigorous safety audits, weekly client reviews, and direct liaison with Alkegen management to manage simultaneous operations in the live plant.

The outcome

The project delivered:

• A watertight, energy-efficient roof system extending the lifespan of the facility.
• Safe encapsulation of asbestos roof coverings, avoiding disruption to operations.
• Enhanced thermal performance, light quality, and durability of the building envelope.
• Internal environments improved for resilience, functionality, and compliance with Alkegen’s production standards.
• Zero lost-time incidents, with health and safety maintained as a top priority throughout.

The successful completion of this technically demanding programme demonstrates Frank Rogers’ expertise in industrial refurbishment in live environments—combining safety, quality, and technical delivery to provide lasting results for global clients like Alkegen.