We were delighted to be chosen by Toray Textiles Europe, a leading manufacturer of high-performance textiles, to install a state-of-the-art single ply roofing system for their headquarters and manufacturing facility. The site is the largest synthetic textile production facility in Europe. Spanning an impressive 43,776 square metres – the equivalent of six football pitches – this project was critical in upgrading the facility’s roof to enhance both durability and energy efficiency. The project allowed us to demonstrate our capability in large-scale industrial projects while ensuring Toray Textiles’ operational and environmental goals were met. 

The roofing project required extensive attention to detail, as we installed 329,000 fixings to ensure the system’s long-term stability and durability. Additionally, we fitted 152,000 thermal insulation panels to enhance the facility’s energy efficiency, aligning with Toray Textiles’ sustainability goals. Given the size and complexity of the project, meticulous resource management and a focus on minimising disruption were key factors in delivering the installation smoothly. 

Several challenges arose during the project, the foremost being the fact that we were working on an operational facility. This required careful scheduling to ensure that our work didn’t interfere with the ongoing activities at Toray Textiles. The variable weather conditions typical of the UK further complicated the project, requiring flexibility to maintain progress safely. The need to meet ambitious energy efficiency goals meant that the installation of thermal insulation panels had to be both precise and effective. Additionally, ensuring the roof’s structural integrity demanded careful installation, vital for the long-term durability of the roofing system. 

A significant external challenge was the fact that the project took place during the COVID-19 pandemic, which caused unprecedented disruptions in material availability and led to rising costs for materials. This required additional collaboration and financial planning to keep the project on track. 

To address the challenge of working on an existing facility, we coordinated closely with Toray Textiles to schedule work in a way that minimised disruption to their production processes. We implemented comprehensive project management strategies to ensure that resources were allocated efficiently and timelines were met despite variable weather conditions. 

Recognising the financial pressures caused by the COVID-19 pandemic, we worked closely with Toray Textiles to agree on a financial package that would ensure the project was delivered on time and within budget despite escalating material costs. By maintaining open communication, we supported them every step of the way, adapting as needed to keep the project on track. Our commitment to effectively managing the financial and logistical aspects of the project helped to ensure the roofing system could be installed in a cost-effective manner. 

We also remained focused on meeting the project’s sustainability goals. Our team installed advanced insulation technologies that significantly enhanced the building’s thermal performance, helping Toray Textiles achieve their energy efficiency objectives. 

Despite the challenges presented by working on an operational site and navigating the escalating material costs due to the pandemic, we completed the project on time and within budget. The new single ply roofing system provided outstanding protection against the elements and will keep the building waterproofed for many years to come.