RAAC Roof Replacement
in a Live Food Production Facility
At a Glance
- Duration: 20 weeks
- Role: Principal Contractor, including RAAC sampling
- Scope: Multi-divisional project from survey, Scaffolding design and M&E to RAAC removal and roof replacement
- Sector: Food Production
- Location: Leith, Edinburgh
Safely Replacing RAAC While Keeping Food Operations Running
When the client and their agent identified structural risks associated with RAAC (Reinforced Autoclaved Aerated Concrete) in a 40-year-old food production facility in Leith, Edinburgh, they required a contractor capable of addressing a complex, high-risk project while maintaining operational continuity and compliance. Based on past successful work and specialist experience in RAAC remediation, Starfish Construction was appointed to lead the design, planning, and delivery of the solution.
Understanding the challenge of live food preparation
The building is a high-specification food production facility used to prepare meals for prestigious catering events across the UK. With residential buildings on three sides, a food-safe internal environment, and live operations throughout the programme, the project presented significant constraints.
A structural engineer commissioned by the client identified RAAC panels in one section of the flat roof and recommended urgent remedial action. After a successful tender submission, we were appointed to manage the project to:
- Evaluate the outline scope of works.
- Provide a remedial proposal.
- Develop a strategy to complete the RAAC removal without impacting production.
Diagnostic and Design Approach
Given the food-safe and operational nature of the facility, we undertook a highly detailed diagnostic process before works began:
Surveys and Planning
- Mechanical, Electrical, and Refrigeration Survey.
- Completed a full assessment of internal services, mapping all interfaces and required isolations to develop a method of work that kept kitchen operations live throughout the project.
- RAAC Core Sampling. Understanding the composition of the panels through core sampling is essential to safely and efficiently deliver RAAC removal projects.
- We conducted intrusive surveys of the RAAC panels to determine material density and identify any screed overlays, enabling the accurate planning of removal timelines and cost estimation. Our experience shows that varying RAAC densities can significantly affect removal methods and safety controls.
Safe Execution in a Live Environment
The RAAC-affected area was situated directly above critical infrastructure, including a walk-in fridge, freezer, and dry goods storage. To protect these and maintain food safety:
- Our NASC-approved Scaffolding Division erected a Fully Weatherproof Temporary Roof to safeguard the building interior from wind and rain.
- We installed an Internal Crash Deck System to protect the operational areas and allow safe, walkable access for RAAC removal works.
- Service Isolation and Reconnection was carefully planned and delivered across M&E and refrigeration systems without service interruption.
- Our sequencing of the works ensured that adjacent kitchen areas remained operational throughout, with no disruption to production.
Full In-House Delivery Model
Operating as Principal Contractor, we delivered all elements of the project using our multi-disciplinary in-house teams, ensuring complete control over programme, quality, and compliance.
Roofing and Design
Our in-house Design team managed all aspects of the new flat roof installation:
- Developing fully compliant, client-aligned specifications
- Coordinating structural assessments and supplier engagement
- Resolving technical challenges collaboratively with the site team to avoid delays
M&E and Service Integration
We managed all service isolations and reconnections in-house, ensuring critical refrigeration and power systems remained protected and reinstated in line with production needs.
Environmental Oversight
Our SEAS division provided comprehensive environmental and asbestos monitoring through:
- Regular air quality inspections and compliance checks.
- Integrated risk management to maintain safety and environmental standards.
- Early identification and resolution of potential delays.
By integrating SEAS into the project team, we maintained a proactive approach to safety and regulatory compliance throughout the project.
- Full removal of RAAC panels and replacement with a compliant roof
- Zero disruption to food production operations
- As-built drawings and warranties
- Final air quality and compliance reports
- Stakeholder satisfaction and client handover
20 weeks
Duration
10/10
Client Project Score
Project Outcomes and Value Delivered
- Zero disruption to food production operations.
- Accurate RAAC diagnosis and costed removal plan.
- Safe sequencing of high-risk works in a live facility.
- Integrated divisional cross-functional collaboration across scaffolding, roofing, M&E, design, and environmental management.
- Full in-house delivery for control, consistency, and compliance.
Why Choose Starfish Construction?
For clients managing operational, food-safe, or high-risk environments, Starfish Construction offers a seamless, end-to-end delivery model. Our integrated teams and proven approach to RAAC remediation provide certainty, safety, and long-term value — even on the most sensitive and complex projects.
Need help with RAAC or building envelope upgrades? Explore our Roofing Services or Contact our team to discuss your project.
Frequently Asked Questions (FAQs)
What is RAAC, and why is it dangerous?
RAAC is a lightweight concrete material used in roofs and floors from the 1950s to the 1980s. It deteriorates over time and can fail without warning, posing a serious safety risk. Building owners and managers have a duty of care to address RAAC issues.
Can RAAC be removed while the building is operational?
Yes. With appropriate sequencing, core sampling, protection measures, and service isolation planning, RAAC can be safely removed without disrupting live operations.
How do you protect equipment during RAAC removal?
We use internal crash decks, temporary roofs, and dust control measures to safeguard sensitive equipment and ensure compliance with hygiene standards.
What makes Starfish Construction suitable for RAAC projects?
We combine RAAC expertise with in-house design, scaffolding, environmental services, and roofing installation, ensuring complete control and compliance throughout the entire process.
"We are extremely pleased with the delivery of our RAAC removal and flat roof replacement project by Starfish Construction. Our Project Manager, Joe, and his team demonstrated exceptional professionalism, clear communication, and attention to detail throughout the project.
We particularly appreciated the seamless integration of Starfish Construction's in-house design team and environmental division, which ensured that all compliance, health, safety, and quality requirements were consistently met.
Challenges were managed proactively and transparently, ensuring minimal disruption to our operations.
The project has been delivered to a standard that fully meets and even exceeds our expectations. We are delighted to award Starfish Construction a score of 10 out of 10 across all areas of delivery."
Client Testimonial
