Chocolate Factory Building Condition Survey
The Project
The Project
RAM Building Consultancy was appointed by CBRE to carry out a comprehensive building condition survey at a chocolate factory. The work comprised two stages:
- Stage 1 Survey – A visual and photographic survey of an initial 16 buildings, to provide an overview of roof, façade, structure, and safety issues.
- Stage 2 Survey – A detailed condition survey of 56 buildings, with report categorising defects by severity, urgency, and recommended action.
The surveys covered a wide range of building types including production facilities, storage buildings, laboratories, historical bathhouses, recreational pavilions, and various ancillary structures.
The Challenges
The Challenges
RAM faced several key challenges during the project:
- Scale and Complexity: The site included 56 buildings, each with varying designs, construction materials, ages, and uses. These ranged from modern structures to heritage buildings with delicate fabric.
- Limited Access: Several areas, especially roofs and voids, could not be accessed directly due to height or safety concerns, necessitating reliance on binoculars, ladders, and photographic evidence.
- Degraded Conditions: Many buildings exhibited signs of extensive weathering, structural fatigue, water ingress, and unsafe occupancy conditions, often resulting from outdated or poorly maintained infrastructure.
- Operational Constraints: Certain buildings remained occupied or operational during the survey, requiring coordination to minimise disruption.
- Historic Structures: Several older buildings had heritage significance (e.g., the Girls’ and Men’s Baths), complicating inspection and recommendations due to preservation concerns.
The Solution
The Solution
RAM’s methodology included:
- Thorough Visual Inspections: Teams performed systematic walkarounds of each structure, using photographic evidence to document over 1,000 defects across the site. Binoculars and ladders were employed to assess roofs and high-level elements.
- Categorisation of Defects: Each defect was classified into key categories:
- Roof
- Façade
- Structure
- Safe to Occupy
- Clear Documentation: A narrative report and an accompanying spreadsheet were created. The spreadsheet detailed:
- Building and location
- Specific defect
- Condition rating (1 to 5)
- Urgency level (Immediate to 24 months+)
- Suggested action and budget estimation
- Structural Insight: Where necessary, RAM identified structural risks and recommended further investigations, such as testing for RAAC concrete panels and assessing overloaded floors.
- Safety Emphasis: Fire safety shortcomings were noted in nearly every building, including issues with fire doors, missing fire stopping, and inadequate balustrades.
The Results
The Results
RAM delivered a comprehensive picture of the estate’s condition, enabling the client to:
- Prioritise Repairs: Buildings and defects were ranked by severity and urgency, allowing CBRE to plan maintenance in a phased, cost-effective manner.
- Mitigate Risks: Immediate risks, such as structural failures, potential fire hazards, and unsafe occupancy conditions, were identified, with clear action plans provided.
- Plan Capital Investment: With RAM’s budgeting and timeline estimates, the client could allocate resources efficiently for roof replacements, façade refurbishment, structural repairs, and fire safety upgrades.
- Improve Occupant Safety: Identification of unsafe conditions (e.g., mould, blocked fire exits, deteriorating parapets) supported enhanced compliance with health and safety standards.
- Preserve Heritage Buildings: Detailed observations on older buildings helped guide sensitive repairs to retain historical integrity while restoring function and safety.
This case study highlights RAM Building Consultancy’s ability to manage large-scale, technically complex building condition surveys with precision and actionable insight, supporting both immediate risk reduction and long-term asset management.
