Large Bakery Serving the QSR Sector

Roof Replacement Project for Large Midlands Bakery Serving the QSR Sector

Overview

In February 2021, Willett Food Projects (WFP) was engaged to review replacement options for the existing ceiling panels at a large Midlands bakery serving the QSR sector. These 1800 × 600 mm gypsum-based panels had begun failing, posing significant health and safety risks to staff, and contaminating the production area with dust and debris from a roof void between the ceiling and the asbestos roof above.

The likely cause was moisture from the baking process saturating the tiles, deforming them beyond the ceiling grid’s capacity. Despite prior roof repairs, water ingress was considered unlikely at the time. WFP’s initial role was to evaluate two quotes obtained by the client for like-for-like panel replacement, but these quotes lacked clarity, detail, and cost certainty.

As a short-term measure, WFP was asked to identify an interim safety net solution to protect workers and provide time to explore longer-term options. However, once the roof was found to be at the end of its service life, the project evolved into a full-scale roof replacement.

WFP created pre-contract information (PCi) and scopes of work and engaged with external contractors to gather accurate costs and programmes. A full costed proposal was presented to the client on 5 March 2021. WFP was formally appointed Principal Designer for the project. Central Insulations was appointed Principal Contractor.

Project budget

The project scope increased significantly during development:

  • Initial ceiling replacement: £2.5 million

  • Final roof replacement: £4 million

Client

Large Midlands bakery serving the QSR sector

Date completed

March 2024

roof replacement project for bakery facility
aerial photo of roof being replaced at a food factory bakery facility
internal shots of roof replacement project by Willett Food Projects

Project delivery

WFP’s involvement began in February 2021 and expanded from reviewing ceiling panel options to managing a full roof replacement. By 9 March 2021, WFP had been commissioned to develop a fully costed solution and liaise with contractors. Multiple design options were reviewed with the site team and refined to three viable proposals.

Contractor engagement started on 23 March 2021, with WFP overseeing site visits and access assessments. On 26 March, WFP gathered costs for a structural assessment. A structural engineer was appointed on 14 April, and their findings confirmed that only minor reinforcement was needed to support a walk-on ceiling system.

By 14 May, WFP presented the final costed options. Only two contractors remained in the bidding process; others withdrew due to the project’s complexity and limited access. This reflected the extended construction programmes that would be required.

Options considered (rejected by client)

  1. Over-cladding and encapsulating the asbestos roof with insulation

  2. Full removal of asbestos roof and ceiling, replaced with new roof deck

  3. Internal insulated panel ceiling matching the roof pitch

Final solution (selected by client)

The client selected an internal food-grade insulated panel ceiling suspended above the bakery, with a walk-on ceiling above, creating a void for service access and additional insulation.

This approach offered several advantages and required significant coordination to deliver. The project was completed while maintaining live bakery operations, presenting a number of unique challenges:

  • The team managed the daily movement of 500 tonnes of tubular steel scaffolding through the only operational airlock

  • Strict food safety protocols had to be upheld during all work

  • The new ceiling design provided a brighter, better-insulated environment, free from leaks and contamination

Engineers on the roof of bakery facility overseeing roof replacement
aerial photo of lorries and HGVs parked at bakery facility during roof project
scaffold in position at roof removal project for Willett Food Projects

Revised roof replacement scope

The updated scope ensured long-term durability and safety, and included:

  • Full removal of asbestos roof and internal ceiling tiles

  • Installation of 120 mm thick FM-approved composite roof panels

  • Upgraded guttering capacity

  • Structural upgrades to support roof penetrations

  • New man-safe roof access system

  • Repainting of high-level internal services

  • Replacement of damaged canopy flashings and purlins

  • Temporary decant of first-floor offices, including removal and reinstatement of ceiling-mounted services and redecorations

Project timeline

  • Feb 2021: WFP appointed to assess ceiling condition

  • Jan 2022: Central Insulations appointed as main contractor

  • Feb 2022: Ceiling replacement works began

  • Aug 2022: Project paused and scope revised

  • Sep 2022: Full roof replacement solution submitted

  • Feb 2023: Central reappointed for revised scope

  • Mar 2023: Roof replacement works commenced

  • Mar 2024: Project completed
red crane swings over the roof of a large bakery facility

Conclusion

This was a highly complex project, delivered under challenging conditions. Despite the operational constraints of a live bakery, WFP successfully managed the transformation of the facility, providing a safer, cleaner, and brighter working environment. The result significantly improved food safety standards and enhanced the bakery’s competitive standing.

Client feedback was overwhelmingly positive. Their customers praised the improvements and began to expect similar upgrades at other facilities, raising the benchmark across the client’s bakery operations.

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Need a feasibility study for your food business? Looking for a new food factory design? We can cover every aspect of your project. Our multidisciplinary team and network of specialist contractors work together to deliver turnkey services for food manufacturers. So, you'll be supported every step of the way.

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