The challenge was to remove over 14,000m² of asbestos cement roof sheeting and plasterboard in a period of 13 weeks followed by installation of a new roof.
This was because Warner Bros. needed to occupy the unit in 13 weeks and start moving in their movie props and they needed a watertight warehouse to do so, free of asbestos.
This was an incredible amount of work and it needed four teams coordinated with four times as many asbestos skips on site, four fork lifts running around site with traffic flow plans and four different roof slopes of composite sheeting in four different compounds to ensure that each team was self-sufficient. This was the only way that we could meet the tight programme.
It was also a condition of Warner Bros. that the building and roof was totally free of asbestos on completion. This involved thorough cleaning of purlins and the warehouse via H vacuums water and industrial floor cleaners on completion.
The solution was to flood the site with four teams of experienced roofing technicians removing the asbestos pitch by pitch. We had to coordinate so as not to flood the warehouse and we had to make sure that the composite panels for the new roof were installed moving along including the ridge bay by bay.
This was a complex operation and included for 20% of new roof lights and a new insulated valley gutter as the existing gutter was also an asbestos cement gutter which had to be removed to comply with Warner Bros. request.
All works were completed two weeks within programme.
Reassurance air tests were performed throughout and swab tests were performed at the end of the works following our thorough sweep of the unit.
The floor was hosed and industrially cleaned to make sure that Warner Bros. were handed a brand new roof and the warehouse was totally free of airborne fibres and any asbestos related substances on the flooring or any of the purlins.
The new roof was a TATA Trisomet composite panel, 110mm to comply with Building Regulations. We incorporated Brett Martin FAIRS roof lights into the installation to provide Warner Bros. their 20% roof area of natural light.
There is now a 25 year warranty on the roof and Warner Bros. have a unit totally free of asbestos related materials.