Successful Restoration of Tower Bakery Post-Water Damage

Introduction

Client: Tower Bakery
Insurer: Sedgwick Internation UK, Lee Ramsey
Duration: 10 week duration, split in to 6 phases

Insurance Peril: Escape of water from burst pipe above ceiling, from multiple points

Work description

Following an initial survey, it was determined that the existing ceiling grid & PVC panelling had suffered extensive water damage and was beyond repair. We recommended a full Electrical Installation Condition Report (EICR) check should be carried out to establish the condition of the current Electrical system prior to commencement of any works to ensure the Electrical system was compliant & safe for future use eliminating the possibility of any further delays once works commence. Upon completion of the EICR it was determined that full lighting rewire was to be carried out within main bakery area and back store area. To facilitate these works a full new containment system was required to house the cabling.  The primary issue being the bakery must be in full production to ensure no loss of earning or business.

The solution to this was to conduct a full review of the business operation and prepare a plan based on how the business could operate out-with the claim affected areas, whilst the works commence.

Initial steps included:

Pre-commencement meeting was arranged with our Client and Tower Bakery representatives to discuss and review the key elements as to how the business operates from point of delivery of the ingredients to the produce being made and dispatched. We also took this opportunity to understand what was most important to our Customer & Client.  The Customer had advised that the most important items were ensuring the business continued to operate as normal to ensure no loss of revenue which would be Approx £35,000 per week & most important to them was no non delivery of contracted obligations that could lead to the loss of the business clients as this would be extremely detrimental to the business continuing to operate in the future. The Customer was also concerned over an upcoming Food Standards Authority inspection that was due within the coming months.

Fully understanding these concern’s, we proposed the business continued its operation as normal from its existing premises with the assistance of the following key elements –

1. Multiple storage containers to be brought to the property which would during the works be used as the bakery’s store.
2. Rear storage area would then be transformed to an operational a confectionary / bakery area fully compliant with the Food Standards Act 1999.
3. Food grade Modular building also compliant with the Food Standards Act 1999 to be sited at rear large enough to undertake the packing / wrapping / dispatch operation of the business.
4. Bakery’s main ovens were unable to be relocated within the Main Bakery Area, Due to this we would then build hoardings completely sealing this area off & provide a poly tunnel from this to the rear store operation allowing this part of the operation to remain during the works (With the oven area to be completed over 1 weekend via split Dayshift & Nightshift as required )
5. Work areas to be fully sealed off from bakery staff to stop any cross contamination from work area to food preparation areas.
6. All works would be completed out with the bakery’s operational hours with a mixture of day, night, back shifts & weekend works with full program of works indicating the key time critical timelines & supplied to our customer / client.
7. We would also ensure all Electrics were fully compliant & certified to Bs7671 following our works.
8. Due to the complexity all works would be overseen by Stellar Insurance Reinstatement Services Operations Manager who would be in direct contact with the customer.
9. Stellar Insurance Reinstatement Services also would provide a Site Supervisor to be onsite for the duration of the works.
10. Full site set up including initiating traffic management plan, delivery of waste management set up, Access for the crane for installation of external modular cabins including walkways.

A temporary work plan was devised which would outline the perimeter changes to the building as well as safe access and egress routes to both contractors and staff.

We at Stellar Insurance Reinstatement Services ltd believe that “Every project is only as good as the work you do prior to commencing” With the above plan put in place we addressed all of our customer & clients concerns allowing for the works & business to progress, Following this we also attended site on multiple occasions ensuring we had taken every eventuality into account & sourcing the correct specialists to assist in the delivery of this project.

Program of works issued to Client & Customer

Main Works:

• All works completed out with the bakeries operational hours, which resulted in a mixture of day, night, back and weekend works to allow no cross contamination within the food preparation areas.
• Works were carried out as per the agreed plan and ran to program.
• Set up temporary lighting within the main working area as well as dust suppression kits.
• Carried out removal of existing grid including isolation of all electrical supplies and removal of lighting fixtures.
• Installation of containment system to house cabling for the new lighting circuits.
• Installation of new grid ceiling within the main bakery area.
• Installation of new lighting/emergency lighting and new vents for mechanical extraction system.
• Replacement of main distribution boards.
• Full clean of the main bakery area.
• Relocation of all machinery back to original locations.
• Commencement of works to rear store area/high risk room i.e. removal of grid, installation of containment and new lighting.
• Removal of all temporary supplies to machinery
• Deep clean of all areas.
• A self-levelling floor screed was applied, followed by installation of non slip commercial grade flooring to rear store area.
• Decommission of all temporary work and site set up.
• Client Handover

Client Feedback

Lee Ramsey, Building Surveyor, Sedgwick International UK

“I’d just like to say a big thanks to the whole team and in particular John McGovern and his on-site team who went above and beyond to keep the project running critically safely and on time.

We rarely give praise, but this project could have so very easily gone wrong on site at various junctures due to its complexity of working on a ‘live’ site, and the fact it didn’t was down to John and his team working hand in hand with the bakery at each stage understanding all stages of the business and tailoring work accordingly to assist.

The policy holder has been effusive in her praise for the whole team at Sedgwick and in particular the site team from Stellar noting the heralding of a “great new chapter in her business “following works, which is the biggest privately own bakery in Scotland!

I look forward to working again on such a large and complex project with your team”.

Angela McKinnon, Tower Bakery

“Great team of guys to work with from the start of the job to the finish. Professional throughout, all positive.”

Response to Feedback

John McGovern, Operations Manager, Stellar Insurance Reinstatement Services

“Thank you very much for the positive feedback on this commercial project.

We are extremely fortunate in that we have a lot of experience within our business that have delivered difficult projects in the past within the commercial sector from working within live working environments to assisting to source commercial buildings suitable for full relocation, then carrying out the full relocation & set up of large commercial businesses to the temporary buildings while works are completed, then once complete relocating the businesses back to original premises.

The time we spent on this project prior to works commencing ensuring we had a full understanding of the business’s operation was key to us producing the best plan on how the bakery could operate while the works commenced.

Our main priority was ensuring the commercial bakery could operate ‘as normal’ with no loss of revenue or business & still comply with Food Hygiene Standards & Health & Safety Guidelines.

This was a great project to showcase what the Partnership of Sedgwick & Stellar can achieve in the Commercial sector – Ensuring that the businesses needs are prioritised, Works programmed to suit the businesses operation & ensuring works are completed under extreme time critical conditions.

We look forward to working together on future projects.”