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Isola Werke UK Ltd

Laminate Board Producer for the I.T. Industry

Isola Werke
View of extended factory from rear which
was here the new factory processing plant
was installed
Factory Refurbishment and Extention to Existing Factory in Cumbernauld. Project value was £4.3m carried out over a period of 52 weeks from Feb 98 to Feb 99.

Luddon Construction were approached by Isola to produce a Design & Build scheme for the new building extensions and the refurbishment of the existing factory whilst not effecting the production capacity output of the factory during the course of the works and to a fixed cost.This was achieved by Luddon Construction working with the client and their advisors in great detail with the planning and development of the client’s exact requirements from start to final hand over. By doing so allowed flexibility in the contrstuction stages to suit the client’s changes which presented themselves during the project duration.

Luddon Construction scope of works involved:

Isola Werke
New Delivery & Distribution Area - part of the
new extension block
The construction of eight new buildings around the perimeter of the existing factory and involved new drainage, foundations, floors (some of which had deep recesses for plant and equipment), structural steel frame with composite roof and wall cladding, internal metal partitions (some as high as 13m) and finishes to walls, floors and ceilings. Tie-ins with the existing building to provide both structural connections and weather sealing. This involved detailed surveys and design detailing. Also the provision for temporary fire escapes had to be provided until the completion of the areas or works. During the works temporary protection and screened off areas were formed to ensure that there was no health & saftey risks to Isola employees.

The refurbishment of the existing factory involved five main areas. Work included the demolition and stripping out of existing structures and finishes within the factory and the laying of new epoxy floor screeds, partitions, wall, floor, and ceiling finishes to both offices and production areas. All toilets, the canteen and laundry areas were upgraded. The provision of a temporary canteen was provided to suit the requirements of the factory workers whilst the canteen was refurbished. During the works temporary protection and screened off areas had to be provided to prevent dust from contaminating the laminated board process. Also to ensure that there was no health & saftey risks to Isola employees.

Isola Werke
New Extension Building
External works involved the construction of a new entrance roadway with controlled gate house and the construction of a 175 space car park with perimeter fencing. The construction of a new electrical substation and control room. Luddon also provided a roof and canopy over an existing chemical storage tanks. Concrete hard standings and builder works attendence where required for mechanical and electrical plant to be supplied and installed by the clients contractors. This involved foundations , bases, plinths, grouting up, bund walls. New steps, ramps and hand rails. New drainage for existing and new works were installed. Soft landscaping involved works to new car park and to a mound at the gable of the new factory extension. Services upgraded included gas and water/fire mains.

Isola Werke
New 20m high tower which would incorporate
a six level plant process unit

Resin Mixing:

A new epoxy floor screed was laid to an area of 360m2 to provide a suitable finish which was resistant to acitone.

Treater:

The Treater was 26m high and the floor slab was designed with cast in steel bearing plates for new 6 level plant process tower. An emergency 2hr fire rated escape stairway was also constructed to provide fire escape means from each plant platform level to the external of the building.

Presses:

This area had some 18 machine pits formed in the ground floor slab ranging from 5m2 to 7.2m2 with a depth from 1m to 3m. There was also rails and duct work cast into the floor for wheeled trollys which had turning bays installed for change of direction.

 

 

Storage:

The building was 12m high and was to accommodate an automatic storage and retrieval racking system and the floor had to be super flat.

Each area of refurbishment had its own special requirement for its end purpose as follows;

Quality Control and Processing: The existing floor slab was of poor surface finish and a new structural screed topping was applied to an area of some 900m2 to provide a high standard of hard wearing finish.

New 20m high tower which would incorporate a six level plant process unit

Canteen:

Isola Werke
View of factory prior to construction works
A temporary canteen had to be constructed utilising new portacabins linked and then fitted out with a full kitchen and canteen facilities to suit Health & Hygiene regulations.

During the course of the works the clients requirements changed by the introduction of new processes which involved various changes. During this period Isola’s output was not affected (infact it increased). This is due mainly to the co-operation of all parties to work together to achieve a common goal.

Works were completed to the satisfaction of Isola and as such we are still carrying out works for them when required to suit changing operations and needs.