Major Refurbishment as Main Contractor at European Oat Millers
While carrying out the external refurbishment to the concrete mill, it was essential that there was minimum impact and disruption to the factory.
In 2014 the Gunite Group was employed as the main contractor for European Oat Millers primary site in Bedford to carry out significant external refurbishment to their concrete mill. European Oat Millers is the second largest oat miller in Europe and processes over 120,000 tonnes of grain each year across its two sites. The Bedford site houses a state-of-the-art manufacturing plant, but the eight storey 1940’s thin walled concrete mill structure required significant refurbishment work as it was suffering from carbonation and chloride contamination. As the site is a busy manufacturing plant it was vital that the remedial works had minimal impact on the running of the factory.
The scope of works for the concrete refurbishment included:
- Setting up site compound
- Internal protection
- Extensive concrete repairs
- Structural steel works
- Roof work
The Gunite Group worked closely with the client W Jordon (Cereals) Ltd as well as key suppliers Flexcrete and Coverspan to ensure that the whole process went smoothly and caused as little disruption to the mill as possible.
Due to the food production nature of the site, the inside of the factory had to be fully protected so no contamination from the building works affected production. Once this was complete the glazing was removed from the outside of the building. The existing coatings were removed by grit blasting then the defective concrete was broken out. High levels of chloride were identified so as to provide protection against further corrosion of the surface applied migratory corrosion inhibitor Cemprotec MCI 2020 was used. All exposed steel reinforcement was treated with Flexcrete’s Steel Reinforcement Protector 841 before areas of spalled and defective concrete were reinstated with Monomix and Monolite. A Curing Membrane WB was applied as a fine mist spray to the surface immediately after finishing to prevent the rapid drying out of the mortars.
Anti-carbonation protection was needed for the external façade in addition to enhancing its appearance. A Monolevel FC fairing coat was used first to fill imperfections and voids. This was followed with an overcoating to provided protection against carbon dioxide diffusion. The choice of protection was vital in this food production environment so the water-based Monodex Smooth was used as its ultra low odour does not release any hazardous solvents.
As the main contractor, we then worked with Coverspan who came in and provided a Kingspan cladding system to replace the original glazing. Then two new canopies were built and encapsulated with the same Kingspan cladding system to finish off the façade.
Here at the Gunite (Eastern) Ltd, we provide our clients with the repair, restoration, protection, and cleaning of concrete, stone and brick structures. Our sister company Gunfire Ltd can also help with all your fire stopping requirements. Give us a call or drop us a line to find out how we can help you today.