Project Overview
We delivered the full replacement of a large-scale commercial curtain wall system within a live leisure facility, alongside associated structural and external reinstatement works. The existing façade had deteriorated significantly and no longer met current compliance or performance standards.
Our objective was to design and install a modern, compliant glazing system while maintaining uninterrupted operation of the facility for members and staff.
Key Challenges
This project presented a combination of structural, operational, and logistical complexities. The existing curtain wall system required full replacement, while the internal slab needed underpinning and reinforcement to support the new façade.
All works were undertaken within a fully operational leisure environment, requiring continuous weather tightness, stable internal conditions, and safe access for users at all times. In addition, below-ground piling works were required beneath the existing structure, demanding careful sequencing and coordination.
Design & Coordination
A collaborative, pre-construction approach was critical to the project’s success. We worked closely with the principal designer to ensure full CDM compliance, alongside the project architect to develop an effective façade solution.
Structural engineers designed the required load-bearing elements, including steel beams and piling systems, while building control approval was secured throughout each phase. This integrated design process ensured that all elements were technically robust, compliant, and fully coordinated prior to construction.
Structural & Façade Works
Significant structural interventions were undertaken to facilitate the new curtain wall installation. These included underpinning the existing slab, installing structural steelwork, and carrying out precision piling works to achieve the required load capacity.
The existing façade was dismantled in controlled phases to maintain structural stability and prevent exposure to the elements. Temporary weatherproofing measures were implemented throughout.
The new curtain wall system was then installed, delivering a high-performance, fully compliant façade that enhances thermal efficiency and significantly improves the building’s visual appearance.
External Reinstatement
Following completion of the façade works, the surrounding external area was reinstated using approximately 200m² of permeable Tobermore block paving. This solution supports effective drainage while providing a durable, high-quality finish aligned with the upgraded exterior.
Live Environment Delivery
Working within an active leisure facility required meticulous planning and execution. We maintained strict segregation between construction and public areas, carefully managed logistics within restricted access conditions, and aligned all activities with the client’s operational requirements.
This ensured the facility remained fully functional throughout the project, with no disruption to day-to-day operations.
Outcome
The project was successfully delivered to a high standard, achieving full compliance with current regulations and significantly improving both structural integrity and building performance.
The new façade provides a modern, future-proofed solution, while the project demonstrates our capability to deliver complex structural and façade refurbishments within live, high-pressure environments—without compromising safety, quality, or client operations
Project Overview
We delivered the full refurbishment of approximately 1,200m² of external terrace at a live leisure facility in Malaspina, Italy. The project involved complete strip-out, structural assessment, waterproofing, and installation of a new high-performance tiled surface.
Positioned directly above an operational spa and changing facility, the terrace required a carefully engineered approach to ensure structural integrity, waterproofing performance, and uninterrupted operation below. The project was managed entirely from the UK, with our specialist in-house team deployed overseas to deliver the works.
Key Challenges
This was a structurally sensitive refurbishment with significant operational and logistical constraints. The active spa and changing areas beneath the slab meant that vibration, load transfer, and construction methodology had to be tightly controlled throughout.
Additionally, delivering the project overseas introduced complexity in coordinating labour, materials, and site operations remotely, while maintaining programme, quality, and compliance standards.
Surveying & Structural Due Diligence
A comprehensive structural and topographical survey was undertaken prior to commencement to assess the load capacity and condition of the existing slab.
Working closely with structural engineers, we developed a methodology that prioritised structural safety. This resulted in a revised construction approach, particularly around the elimination of mechanical plant and the adoption of low-impact removal techniques.
Strip-Out & Methodology
Due to the sensitivity of the structure, all strip-out works were carried out using low-vibration, manual methods. The entire 1,200m² terrace was removed by hand using specialist tools, ensuring no adverse impact on the operational facility below.
This labour-intensive approach required detailed sequencing, increased workforce coordination, and strict on-site quality control to maintain both safety and programme efficiency.
Waterproofing & Preparation
Following removal, a full tanking system was installed to provide complete waterproofing protection to the areas below. This stage was critical in safeguarding the spa and internal spaces from water ingress.
The terrace was then re-levelled, with precise falls introduced to ensure effective drainage. Movement joints were incorporated throughout to accommodate thermal expansion and enhance long-term durability.
Installation Works
The final finish comprised the installation of 900 x 600 porcelain tiles across the full terrace area. Tiles were laid to exacting tolerances, aligned with designed falls to optimise drainage and achieve a clean, uniform appearance.
Additional features included protective picket fencing around ventilation domes and the integration of artificial grass sections to soften the aesthetic and create a more balanced external environment.
Logistics & Overseas Delivery
The project was delivered entirely under UK management, with our in-house team mobilised to Italy. Detailed logistical planning ensured seamless coordination of materials, labour, and site activities despite the challenges of international delivery.
Close control was maintained throughout, ensuring programme adherence, quality assurance, and efficient execution on site.
Outcome
Completed in under three months, the project delivered a fully refurbished, structurally secure, and visually enhanced terrace. All works were executed safely and compliantly, without disruption to the operational spa and facilities below.
This project demonstrates our capability to deliver complex refurbishment works in structurally sensitive and live environments, both within the UK and internationally, combining technical expertise with precise execution.
Project Overview
We delivered a fully bespoke sauna installation as a complete turnkey solution, managing the project from initial concept through to final commissioning. Unlike a standard installation, this was a ground-up build incorporating full structural construction, services integration, and premium finishes tailored to the client’s requirements.
All design development and pre-construction planning were undertaken at our warehouse facility, where we collaborated closely with the client to refine layout, specification, and detailing. The sauna was templated and partially pre-built off-site before installation, ensuring precision, efficiency, and a high-quality final finish.
Approach
Our off-site manufacturing approach allows clients to fully visualise and refine their sauna prior to installation. By constructing key elements within a controlled environment, we maintain strict quality control while significantly reducing on-site disruption.
This methodology enables us to deliver both commercial and domestic sauna projects efficiently, whether new-build installations, refurbishments, or full replacements.
Design & Build Scope
This project involved a complete redesign and new structural build. All elements were constructed from first principles, including wall systems, insulation layers, and internal configurations.
The scope included full integration of all essential systems, such as electrical services, heating, lighting, and ventilation. Every component was carefully specified to ensure optimal performance, durability, and user experience.
Materials & Specification
The sauna was constructed using premium-grade thermo timber, selected for its durability, dimensional stability, and refined aesthetic. High-performance foil insulation systems were installed to maximise thermal efficiency and ensure consistent heat retention.
All internal benching was bespoke manufactured and installed, designed to optimise ergonomics and comfort while maintaining a clean, contemporary finish.
Systems Integration
A fully integrated system was delivered as part of the installation, including the sauna heater, lighting, and temperature controls. All systems were connected back to the plant room, allowing for efficient operation and simplified maintenance.
Commercial-grade safety features were incorporated, including a panic alarm system, ensuring full compliance with safety requirements.
We offer flexibility across projects, with the capability to install both electric and traditional heating systems depending on client preference and project specification.
Additional Works
As part of our turnkey service, we also deliver associated elements such as floor tiling, drainage, and ventilation systems. This integrated approach removes the need for multiple contractors, ensuring consistency in quality, programme, and delivery.
Outcome
The project was delivered as a high-specification, fully integrated sauna installation, combining structural integrity, technical performance, and premium finishes.
By managing the entire process—from design and off-site preparation through to installation and commissioning—we ensured full control over quality, efficiency, and execution.
Why This Matters
This project demonstrates our capability to design, manufacture, and install bespoke sauna solutions across both commercial and residential environments.
Our turnkey approach, combined with off-site precision and on-site expertise, enables us to deliver high-quality installations with minimal disruption, while maintaining exceptional standards of craftsmanship, safety, and performance.
