A recent refurbishment project required complex structural interventions, particularly when integrating significant new services within an already established and operational facility. These situations demand careful planning, innovative engineering, and precise execution to ensure the client’s operations remain uninterrupted. We faced a unique challenge: restricted head height within a live facility meant we needed to adapt the existing structure to create sufficient space for our client’s new equipment. The solution involved removing a main structural 40-metre-long concrete beam, an element critical to supporting the loads of the operational building.

This was no small task. Our team safely and efficiently removed 31.5 tonnes of concrete by dividing the beam into 21 manageable sections, each weighing approximately 1.5 tonnes. With every stage of demolition, we installed complex temporary works to ensure the building remained structurally secure, protecting both the integrity of the facility and the safety of those working within it.

Once the original deep concrete beam was removed, we replaced it with a new, shallower steel beam.

This innovative solution maximised the available headroom while maintaining the required structural performance, enabling the installation of the new services without compromising the building’s stability. Equally important was our commitment to ensuring ‘business as usual’ for our client throughout the works. To achieve this, we deployed vibration sensors across the facility, continuously monitoring activity to confirm that pre-agreed thresholds were never exceeded.

This careful control guaranteed that the project progressed smoothly, with no disruption to ongoing operations. This project is a prime example of how BES combines engineering expertise with meticulous planning to deliver complex refurbishments in challenging live environments.