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Dawn meats are a major supplier of beef and lamb to the retail sector, with major clients such as Tesco, Sainsbury and Marks and Spencer.
Having completed many projects for Dawn over the years, Impact were invited to tender for a major refurbishment project at their Carnaby meat processing centre, which included replacing ninety metres of old drainage channels with new stainless steel, installing fifty metres of new stainless steel kerbs to the loading bay area and boning hall, installing in excess of three hundred metres of new concrete kerbs complete with polyurethane coving, and over fifteen hundred square metres of new polyurethane flooring.
Initially, we were asked to survey the areas of the plant in question, and had detailed discussions with Dawns project engineers on how the project could be completed, with minimum disruption to production and in conjunction with the white wall panel installers.
A programme of work was agreed that would allow us to complete some areas during normal Monday to Friday working, but to facilitate production, the programme included a lot of out of hours working and weekends.
Work on the project commenced in the tray wash area in February, and carried on through the main boning hall, loading bay and various ancillary rooms. We firstly supplied and installed new stainless steel drainage channels, with gulley outlet and trap to each area, piped into Dawns existing drainage system. Due to the time constraints, the new channels were set into a polyurethane bulk screed, which, although more expensive than the traditional concrete, meant that the new surrounding Polyurethane screed could be, and was, installed the following day.
Following the flooring, we then installed a 350mm high polyurethane coved skirting onto the new concrete kerbs to complete each area.
All of the preparation, from excavation of the drain gullies to Beff milling of the floor surfaces, was carried out ‘in house’ by Impact,Flooring. All of our preparation is now carried out in house by our own operatives, allowing us greater quality control without the need for outside preparation contractors.
On completion of the preparation process, all of the entire floor areas were vacuum cleaned and inspected ready for the new polyurethane screed installation.
Dawn meats had specified that a red polyurethane screed and coving system was their requirement, so a Resdev system, Pumadur HF 9mm floor screed and Pumadur WR coving, was chosen. Impact Flooring have successfully installed this floor and coving system many times on projects for clients such as Dr Oetker, Pork Farms, Greggs Bakeries, KFC and Muller Wiseman and we have great confidence in its appearance and durability. Dawn Meats favoured this system as it surpasses all of the requirements of their BRC audits.
Each phase of the project installation process was duly completed and handed back to Dawn Meats, with each of the areas, with the help of new hygienic white wall panels, transforming a dated meat processing centre into a modern, new food production environment.