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Ice Factory, GrimsbyAppraisal of Existing Structureby Alan Baxter & Associates LLPwith Richard Griffiths Architectsand KMCS (Cost Consultant)February 2010
Alan Baxter
Ice Factory, GrimsbyAppraisal of Existing Structureby Alan Baxter & Associates LLPwith Richard Griffiths Architectsand KMCS (Cost Consultant)February 2010
Alan Baxter
Contents1.0 Summary..........................................................................................................1
2.0 Introduction....................................................................................................2
3.0 HistoryoftheBuildingandtheSite......................................................3
4.0 Geology............................................................................................................5
5.0 FormofExistingStructure........................................................................7
6.0 ObviousDefectsintheExistingStructure....................................... 13
7.0 ProposalsforRemedialWorkstotheExistingStructure........... 19
8.0 ProposedAlterationstotheStructure.............................................. 22
9.0 NextStage.................................................................................................... 23
10.0 ExistingFabric,byRichardGriffithsArchitects(RGA)................. 24
11.0 CostEstimate,byKMCS.......................................................................... 25
Appendices............................................................................................................. 27
AppendixA–InformationReceived........................................................................... 28
AppendixB–DrawingsbyABA.................................................................................... 29
AppendixC–DrawingsbyRGA.................................................................................... 30
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1.0
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Ice Factory, Grimsby Appraisal of Existing Structure / February 2010Alan Baxter
1.7 Thesebuildingshavenotbeenmaintainedinanyformformanyyears,probablywellinexcessofthe20yearssincetheyfellintodisuse.Rainwateriscascadingthroughthebuildingsfromtoptobottom.
1.8 Overall,andmostlyasaresultofthetotallackofmaintenance,combinedwiththeaggressiveenvironmentcreatedinthebuildingsfromthemanufactureoficeinvolvinghugevolumesofwatermovingaroundthebuildings,thestructureisnowinaverypoorstateindeed.
1.9 Intermsofanormallifecycleforbuildingsofthisnature,thesebuildingshavemissedtheirlasttwomajoroverhaulsandarenowdegradingatarapidlyincreasingrate.
1.10 Thefollowingnotesdescribetheaboveingreaterdetailtogetherwithproposalsforthelikelyremedialworksrequiredtotrytoaddresstheobviousdefectsinthestructure,allinaccordancewiththeScopeofWorkssetoutbytheNELC.
1.11 Itdoesappearasifthebasicstructuretothebuildingscanbemostlyretainedthoughthereissomeextensiverepairandimprovementsrequired.
1.12 AConservationStatementisrequiredtocomplementthisstudyandhelptounderstandwhatishistoricallyimportantaboutthesebuildings,andtoestablishaclearandproperinterpretationoftheirculturalvalue.
1.13 ReferalsotothelatersectionsonthefabricofthebuildingbytheArchitect,RichardGriffithsArchitects,andthecostestimatesforthelikelyworksbytheQuantitySurveyor,KMCS.
1.14 ThebasicestimatedcostbyKMCSofthethreeoptionsdiscussedwithNELCare:
(C) Tobringthebuildingstoare-usablestandard £4.75M
(B) Areducedversionof(C) £3.5M
(A) TemporaryProtectionwithsomeUrgentStructuralRepairs £1.5M
RefertoSection11.0forfurthercostinformation.
1.0Summary Structure
1.1 TheIceFactorycomprisestwomainbuildingsbuiltin1900/1901and1907/1910.Thereisasmall1950sextensiontothefirstbuilding.ThebuildingsareListedGradeII*.
1.2 Thestructuretothesebuildingsistypicalofindustrialbuildingsoftheirtimewithloadbearingbrickworkwallsandinternalsteelcolumnssupportingsteelandtimberroofsandfloors.
Theformofthestructure,however,isveryparticulartothepurposeofthebuildings,thatis,tomanufactureverylargepiecesoficeforthefishingindustry.
Inplacesthestructuretothebuildingformsapartofthestructuretothemachine/workingsoftheicemakingprocess.
1.3 Thebuildingsarelargeandaretypicallyaround10mhighwithsomeareasextendingalittlebelowgroundlevel.Somespaceshaveafull10mclearheightandotherscompriseofthreestoreys,e.g.twostoreysoficemakingoveranundercroftforthedistributionofservices.
1.4 Itappearsthattheoriginaldesignandconstructionofthestructurewasofareasonablequalityproducingsomerobuststructures,necessaryfortheheavydutymanufacturingprocesscarriedoutwithinthebuildings.
1.5 Thefoundationsgenerallyappeartohaveperformedwelltodatealthoughinonecornerofthe1907/1910buildingthepatternofcrackinginthebrickworkwallsuggeststheremayhavebeensomedifferentialsettlementofthefoundation.Atpresentlittleisknownabouttheformofthefoundations,thoughgiventhepoorgroundconditionsillustratedonthelocalgeologymapsandboreholesobtainedfromtheBritishGeologicalSocietyitseemslikelythefoundationsaresupportedontimberpiles.
1.6 Astheicemakingprocesshasdevelopedthroughouttheworkinglifeofthesebuildingstherehasbeenaneedforsomealterationstothestructurethoughthesedonotappeartohavebeenofmajorstructuralsignificance.
2.0
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2 Ice Factory, Grimsby Appraisal of Existing Structure / February 2010 Alan Baxter
2.0Introduction2.1 AlanBaxter&AssociatesLLP(ABA)havebeeninstructed
byNorthEastLincolnshireCouncil(NELC)toleadateamofconsultantstocarryoutanappraisaloftheexistingstructure,allinaccordancewiththesubmissiontoNELCdated26.06.09,theApproachandMethodologysubmittedon30.07.09anddiscussionswithNELCon17.09.09,14.01.10and27.01.10.
2.2 Theothersintheteamofconsultantsare:
RichardGriffithsArchitects(RGA)andKMCS(QuantitySurveyors)
2.3 Thefollowingreportisasummaryofourappraisalandcomprisesthreemainelements:
(i) Structuretothebuilding ByABA
(ii) Fabricofthebuilding ByRGA
(iii) CostEstimateofproposedworks ByKMCS
Itisbasedonourdesktopresearch,togetherwithwhatweareabletoseefromourvisitstothebuildingon17/09/09and14/01/10andtheoutputfromworkshopsheldatABA’sofficeswiththeconsultantteam,andwiththeclient.
2.4 AccesstothebuildinghaskindlybeenprovidedbyAssociatedBritishPorts(ABP)thoughinternallyaccessisseverelyrestrictedduetotheunsafenatureofthefloorstructuresinmanyplaces.
View from Gorton Street
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3.0
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Ice Factory, Grimsby Appraisal of Existing Structure / February 2010Alan Baxter
3.0History of the building and the Site3.1 TheIceFactorycomprisesoftwomainbuildingsseparatedby
arailwayline(nolongerinuseandcoveredover).Themainbuildingtothesouthoftheoldrailwaywasbuiltin1900/1901byTheGrimsbyIceCompanyandwasthelargestofalltheicefactoriesinthetown.
3.2 TheFactorywasextendedin1907/1910withtheconstructionofthebuildingtothenorthoftheoldrailwayline.
3.3 In1930/1933theFactorywasmodernisedwiththeoldsteamdrivenplantreplacedwithelectricitydrivenplant.Thisapparentlyaffectedthemachineryanditsfittingsmorethanitsfabric.Aspartofthisworktheoriginalboilerhousechimneywasdemolishedthoughitsbaseremains.
3.4 Intheearly1950stheoriginalFactorywasextendedtoincorporateanewcompressorroom,togetherwithotheralterationstotheicestores.
3.5 TheIceFactoryclosedin1990andhasnotbeeninusesince.
3.6 ThebuildingswerelistedgradeII*on12September1990.AcopyofthelistingisenclosedinAppendixA.
View from Fish Dock Road Aerial view
3.0
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1905Recent aerial photo
TheIceFactory
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4.0
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Ice Factory, Grimsby Appraisal of Existing Structure / February 2010Alan Baxter
4.0Geology4.1 Thegeologymapofthisareashowsthemajorityofthedock
builton‘landslip’overAlluviumoversandsandgravels.
Geology map
TheIceFactory
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4.2 BoreholesobtainedfromtheBritishGeologicalSocietyshowthesitetobeunderlainbymadegroundoversoftsilt,peatandclaywithsomethinlayersofsand,overchalkwhichisfoundaround80ft(24mm)belowgroundlevel.
4.3 NodetailsofthefoundationstotheIceFactoryhavebeenobtained,butitisdocumentedthattheGrimsbyDockTowerbuiltin1851isfoundedontimberpilesprobablydrivenintotheclay.ItseemslikelythattheIceFactoryisalsosupportedontimberpiles.
4.4 Boreholesfrom1925showedadepthtogroundwaterofaround15ft(4.57m),whereasin1950thedepthisshownas21ft(6.4m)andfrom1981adepthofaround10ft(3m)isrecorded.
BGIS Borehole Ref TA21/64A or Ref TA21SE/21A from the Ice Factory engine house
BGIS Borehole location plan
TheIceFactory
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5.0Form of Existing Structure5.1 Thesebuildingscompriseoffairlyconventionallate19thearly
20thCenturyindustrialstructuresformingsuchspacesasaboilerhouse,compressorrooms,switchroomsandofficese.g.areas(i),(iv),(v)and(ix),alltheretosupporttheprincipalpartsofthebuildingwheretheicewasmanufacturedorstored,ieareas(ii),(iii),(vi)andvii).Intheseice-makingareasthestructureformspartofthemachineryusedtomaketheice,andalsosupportsthecasing/envelopetothemachines,ietheroofandwalls.
Key planWatertankonroof
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Nexttothisspaceisthe1950sextensioncomprisingofaswitchroomwithanofficeatfirstfloorlevel,andthenanotherdoublestoreyheightcondenserroom.Thepitchedroofovertheofficeappearstobeoftimberceilingjoistsandrafterssupportedonsteelbeams,andthefirstfloorcomprisesofafillerjoistfloorslabspanningbetweensteelbeams.Thenewcondenserroomroofappearstobeofin-situreinforcedconcreteslabspanningbetweensteelbeams.Thesteelbeamsaresupportedonsteelcolumnsbuiltintothebrickworksidewalls.
Alargewatertankissuspendedabovetheroofoftheoriginalcondenserroomonasteelframewhichspansbetweentheloadbearingwallsatrooflevel.
(i) CompressorHouse,SwitchRoomandOffice:
Theoriginalcompressorhousecomprisesatallsinglestoreyspacearound9metreshigh,withsolidloadbearingbrickwallssupportingsteelroofbeamsandaconcretefillerandsteeljoistflatroof.Thelongerspanningroofbeamsareproppedoff3steelcolumnstowardsonesideoftheroom.Thesecolumnsalsosupportderrickcranesforservicingthecompressorsintheroom.
Thegroundfloorisofsolid,probablyreinforcedconcreteconstructionwithnumerousservicestrenches/pitsincorporatedintotheslab.Itislikelythattheveryheavycondenserplantisfixeddowntothickreinforcedconcreteplinthsaspartoftheslab.
Services trench in ground floor
Typical section through Compressor Room
Water tank on roof
Compressor Room roof
1950s Compressor Room
Original Compressor Room
GableendtoTankRoom
Fillerjoistroofslab
Travellingpulleybeam
RCslabwithpitsandservicetrenches
Derrickcrane
Steelbeam
Steelcolumn
CompressorSection
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(ii) TankRooms:
Thisisthemainpartoftheoriginal1900buildingandcomprisesoftwofloorsoficemakingmachineryoverasemi-basementundercroft,allcontainedwithinanexternalloadbearingbrickwork,andinternalsteelframedstructure.
Accessisseverelylimitedforsafetyreasonswithnoaccessavailabletotheundercroft.
Thestructuretothetwobaybuildingcomprisessteelrooftrussessupportingtimberpurlins,timberboardsandslates,spanningbetweenpiersinthebrickworksidewallsandarowofsteelcolumnsonthelineofthecentralvalley.
Thereisasmallbrickworktowerattheeastendofthetankroomswhichappearstobesupported,inpartoffthesteelframe.
Some equipment remains in Tank Room Internal column support to travelling crane brackets1st floor Tank Room
Typical section through 1900/1901 Tank Rooms
Rooftruss
CIBrackets
Undercroft
Travellingcranebeam
Travellingcranebeam
1stFloor
UpperGroundFloor
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Thetwofloorsoficemakingequipmentaresupportedoffagrillageofsteelbeamsspanningbetweenthesidewalls,thecentralrowofsteelcolumns,andtwofurtherrowsofcolumnsineachbayofthebuildingintheundercroft.
Travellingcranesspanclearacrosseachbayaboveboththetwofloorsoficemakingequipment,supportedoffcastironbracketsattachedtothepiersinthebrickworksidewallsandthecentralrowofsteelcolumns.Thecastironbracketsonthepiersarefixedthroughthebrickworktoexternalplates.
External plates to crane beam brackets
Bracket support to travelling crane beam
View of 1907/1910 Tank Room roof
Roof over Ice Store Original Boiler House
(iii) IceStore:
Thispartofthebuildingcomprisesofathreestoreyexternalloadbearingbrickworkwallsupportingaflatroofofsteelbeamswithprobablyafillerjoistslab.Ithasalsobeenconvertedforicemakingandsocontainstravellingcranesandicemakingequipmentontheuppertwostoreys.Thesemibasement/undercroftiscurrentlyastoreroomfulloffridges/freezersandwasnotaccessible.
(iv) FlakeIcePlant(PreviouslyBoilerHouse):
Thissinglestoreystructurehasloadbearingbrickworkwallssupportingasteeltrussedroofwithtimberpurlins,boardsandslates.
Originallytheboilerhousehadatallbrickchimneyinthenorthernmostcorner,butthiswasremovedaspartofthemodernisationinthe1930s.Itappearsasifthebasetothischimneyremains.
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(v) CondenserRoom/Stores:
Theseareasofthebuildingaregenerallyoftwostoreyswithabasement/undercroft.Accesswasnotpossibletothebasement.Thefloorandroofstructuresappeartobeoffillerjoistconstructionsupportedonsteelbeamssprungbetweenloadbearingbrickwalls.
(vi) TankRooms:
Thisisthemajorpartofthe1907/1910extensionandisofsimilarconstructiontotheoriginaltankroomstructurein5.2(ii)above.
Thebuildingprovidedtwostoreysoficemakingequipmentsupportedbysteelgrillagesatboththefirstfloorandgroundfloorlevels.Travellingcranebeamstothefirstfloorandthegroundfloorarebothsupportedononesidebycastironbracketsinthepierstothesolidloadbearingbrickwallandontheotherbybracketsontosteelcolumns.
Thelowerlevelsteelgrillageissupporteddirectlyoffthereinforcedconcretegroundfloor.Thefloorisformedinsuchawayastoprovidethreetrenchesthefulllengthofthebuilding.
Thereisasmallbrickworktoweratthenorthendofthetankroomwhichappears,atleastinpart,tobesupportoffsteelbeams.
1st floor 1907/1910 Tank Room Ground floor steel grillage Ground floor brench and foundations to brick pier
Typical section 1907/1910 Tank Room and Ice Store
Timbertrusses
Travellingcrane
Travellingcrane
1stfloor
SteelgrillageontopofRCtrenches
Steelbeam
Steelcolumn
IceStore TankRoom
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5.2 Thereisasmallpedestrianbridgebetweenthe1900/1901andthe1907/1910buildingscomprisingofsteelbeamsspanningbetweentheexternalwallsofeachbuildingwithatimberboardeddeck.
5.3 Theseareunusualbuildingswithsomeverylargeopenspacessuchasthestoreinthe1907/1910buildingwhichhasloadbearingbrickworkwallsofaround10mhigh.
Theoverallstabilityofthebuildingsappearstorelyonthestiffnessoftheboardedroofstructureandthefloorstructurestoactashorizontaldiaphragmstyingtogetherthewalls.
Thegroundfloorappearstobetimberboardedoversteelbeamspossiblyoveranundercroft,butsafeaccessherewasnotpossible.
(viii) LoadingBay:
Thisareawasnotaccessiblebutitlooksasiftheflatroofstructureispossiblyofsteelfillerjoistconstructiononsteelbeamssprungbetweensolidloadbearingbrickworkwalls.
(ix) Office:
Atthewestendofthetankroomthereistwofloorsofofficeswhichappeartosimplybeanextensionofthetankroomstructurewithsomepartitionsandfalseceilingsaddedtocreatethespace.
Theroofcomprisessteeltrussesspanningacrossthewidthofthebuildingfromtheexternalloadbearingbrickworkwalltotheinternalcolumns.
(vii) IceStorageArea:
ThisisineffectasideextensiontotheTankRooms(vi)aboveformingasingleverytallstoreyheightspaceofover10m.
Theroofstructurecomprisestimbertrussessupportingtimberpurlins,rafters,boardsandslates,spanningbetweensteelvalleybeamssupportedoverslendersteelcolumns.
Base of internal columns between Tank Room and Ice Strore Bridge between buildings
Ice Store roof Roof over end of Tank Room by Offices Bridge between buildings
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6.0Obvious Defects in the Existing Structure6.1 Thefourcriticalissuesinassessingtheoverallconditionofan
existingstructureare:
(i) TheQualityofOriginalDesignandConstruction.
(ii) ThePerformanceofitsFoundations/thequalityofthegroundonwhichtheyarebuilt.
(iii) PreviousAlterations.
(iv) Howwellithasbeenmaintained.
6.2 TheQualityofOriginalDesignandConstruction:
Fromwhatwecanseetheoriginaldesignandconstructionwasgenerallyofanaboveaveragequalityforindustrialbuildingsofthisage,thoughtheprocessoficemakingwithlotsofwaterthroughoutthebuildingandtheabrasivenatureoftheicemakingprocesscreatedafairlyaggressiveenvironmentforboththeexposedsteelstructure,andthosesteelelementsbuiltintotheexternalwallsandroof.
Surface corrosion and impact damage to steel beams
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6.3 ThePerformanceofitsFoundations:
TheBGISboreholesindicatethatthewholeofthedockisunderlainbyasignificantdeptofsoftmaterialincludingpeat,withthefirstlayerofreasonablesoilcapableofsupportingheavystructuressuchastheIceFactorybeingtheboulderclayataround10mdepth.ItthereforeseemslikelythatthefoundationstotheIcefactoryareondriventimberpiles.
Therearemanycracksintheloadbearingbrickworkwallsthoughthesegenerallyseemtoberelatedtoproblemsassociatedwiththecorrosionofsteelworkbuiltintothewalls,thermalmovementsoftheuninsulatedroofsandnotobviouslytodowithmovementofthefoundations.
Theoneareawherethecracksinthewallsmayberelatedtodifferentialsettlementofthefoundationsisthenorthwesternendofthe1907/1910buildingwherethereisacrackalmostfullheightofthewalls,andappearstobewideratthetopthanatthebottom.ThisisinthecorneroftheIceStore.
Generallytheexistingfoundationsappeartohaveperformedreasonablywelltodate.
6.4 PreviousAlterations:
AswithanyindustrialbuildinghousingaprocessovermanyyearstherepeatedupdatingoftheprocessgenerallyinvolvessomealterationtothestructureandthisisthecasehereintheIceFactory.Overall,however,thesealterationsdonotappeartohavesignificantlyaffectedtheexistingstructure.
6.5 MaintenanceoftheStructure:
Fromthestateofthebuildingsitisclearthattheyhavenotreceivedanymaintenanceformanyyearsprobablyfromwaybefore1990whenthebuildingswerelastinuse.Largeareasoftheroofcoveringshavebeenremoved,orhavecollapsedandarenowinsuchapoorstate,thatrainwateriscascadingtoptobottomthroughthebuildings.
This,togetherwiththeaggressiveenvironmentgeneratedbythewaterbaseduseofthebuilding,hasledtosomeextensiveandsignificantdegradationofthestructure.
Themostobviousfactorinthedegradationoftheinternalstructureovertimeisnaturallytheprolongedexposureofthetimberandsteelstructuretowaterasaresultoftheicemakingproduction,leadingtocorrosionofthesteelworkandwetrotinthetimberstructure.Severalsteelbeamshavealsosufferedfromrepeatedcollisionswithotherheavymetalitems.Thiswas
Cracked brickwork in Ice Store Cracked brickwork in Compressor Room
Cracks in parapet walls Roof to 1900/1901 Tank Room
Physical and corrosion damage to steelwork
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visibleinbeamsoverlargeopeningsintheexternalwalls,andalsointernallywherethemovementoflargesteelitems(egcansfortheicemaking)clearlyresultedinalotofphysicalclasheswithsomeofthestructure.
6.6 ExternalWalls:
6.6.1 Drawingsnumbers1568/01/15and16showelevationsoftheexternalbrickworkwallsmarkedupwithourobservationsontheobviousstructuraldefectsegapproximatelocationofcracksandtheirlikelycause.
Basedonwhatwecouldsee,thecracksinthebrickworkweregenerallyasaresultofcorrosionofsteelworkbuilt
Impact damage to brickwork around opening in wall
Spalled concrete as a result of corroded reinforcement
Crack in parapet to roof over Ice Store
Cracked concrete where reinforcement is corroding
Roof beam and filler joist roof by 1900/1901 Ice Store
RC frame around windows in 1950s extension
intotheexternalwalls,togetherwithsomethermalexpansionoftheuninsulatedflatroofsandlocallysomeimpactdamage.
6.6.2 RefertotheArchitect’sdrawingsfornon-structuralissuessuchasminorcracks,weatheringetc.
6.6.3 Thereinforcedconcretewindowframeinthe1950sofficeandcondenserroomsisinapoorconditionwithspallingoftheconcreteinseveralareasasaresultofprolongedrainwaterpenetrationoftheconcretecausingthereinforcementtocorrode,expandandpushofftheconcrete.
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6.7.5 Alloftheotherflatroofsappeartobeoffillerjoistconstructionandinseveralareastheconcretecovertothebottomofthesteeljoistshasspalledexposingcorrodedsteelwork.Thisisevidentinthecompressorroom,icestoreandcondenserroomroofsintheoriginalbuilding.Wesuspectthisisalsothecaseintheroofstotheloadingbayinthe1907/1910extension.
6.7.3 Thetimberstructuretotheshallowpitchedroofovertheofficeinthe1950sextensionislikelytobeinaverypoorconditionandsomeofthesupportingsteelbeamsalsoappeartobesignificantlycorroded.
6.7.4 Wenotedsomespallingofconcretelocallyinsomeareasoftheundersideofthereinforcedconcreterooftothecompressorroominthe1950sextensionsuggestingrainwaterhasbeenpenetratingtherooffinishesandtheslabformanyyears.Itislikelythattherewillbeotherareaswherethereinforcementiscorrodedespeciallyinthetopoftheslab.
6.7 RoofStructures:
6.7.1 Generallythetimberboardingandpurlinstothepitchedroofstotheoriginaltankroomsandboilerhouseappeartobeinapoorstateasaresultofprolongedrainwaterpenetration.Thesteeltrusses,however,seemtobeinareasonableconditionthoughitwouldbeprudenttoexpecttofindsomelocalproblemstodowithcorrosionespeciallyalongthevalleyguttertotheoriginalbuilding.
6.7.2 Thetimbertrussestotheicestoreinthe1907/1910buildingarelikelytohavebeenmuchmoreaffectedbyrainwaterpenetrationthanthesteeltrussesandsowewouldexpecttofindsomeextensivewetandperhapsdryrotespeciallyintheendsofthetrussesalongthevalleyguttersandaroundtheedgeofthebuildingundertheparapetgutter.
Roof to 1950s Office
Severely corroded steel joist in flat roof
Roof over Ice Store
Original Compressor Room
Roof to original Tank Rooms
1950s Compressor Room
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6.8 InternalStructure:
6.8.1 CompressorRooms(i)
Rainwaterpenetrationovermanyyearshasledtosomesignificantcorrosionofthesteelbeamstothefirstfloorintheoffice.Thesteeljoiststothefillerjoistfloorarealsolikelytobeaffected.
Elsewhereinthecompressorroomstheinternalsteelstructuregenerallyappearstosufferfromsomesurfacecorrosiononly,whichisnotofmajorstructuralsignificance.
Theconcretegroundfloorinallofthisareacontainsnumerousservicestrenches,plinthsandrecesses.Sometrencheshavesteelcovers,andsomearepartiallyfilledwithwater.
6.8.2 TankRooms1900/1901(ii):
Thesteelstructureabovefirstfloorlevelgenerallyappearstobeinapoorconditionasaresultoftheprolongedrainwaterpenetrationthroughthebuilding.Atthislevelthemostobviousdefectissurfacecorrosionofthesteelworkandthisvariesconsiderablywithonlylocalareasthatappeartobesignificant.
Whilstverylimitedaccesswaspossibleacrossthisareaofthebuilding,itappearsthatatfirstfloorlevel(ietheuppericemakinglevel),theeffectoftherainwaterandtheaggressiveenvironmentduringtheicemakingprocesshasleftthetimberboardedfloorinaverypoorstateandboththeextentandseverityofcorrosionofthesteelframedstructureismuchmoreseriousthanabove.
Attheuppergroundfloorlevel(iethelowericemakinglevel)theconditionofthestructureappearstobeevenmoredeterioratedthanatfirstfloorlevel.
Noaccesswaspossibletotheundercroft,asitwasmostlyfilledwithwater,butfromwhatcouldbeseenfromtheentrance,thesteelworkatthislevelisinanextremelypoorstate.Onlyafewbeamsandcolumnswerevisibleandthesewereseverelycorrodedanddelaminatingtosuchanextentthatinplacestheflangeandpartsofthewebofthebeamsandcolumnsweremissing.
Itislikelythatthefloortotheundercroftisalsoinaverypoorstate.
First floor to 1950s Office Services trench in Compressor Room ground floor
First floor Tank Room
Severely corroded steel column in Tank Room undercroft
Severely delaminating steel beam in Tank Room undercroft
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Thesteelcolumnssupportingtheroofandfirstfloorhaveheavilygussetedbaseswheretheyarefixedtothetopofthegroundslab,whichisthickenedateachcolumnpositionandmustalsobethefoundationtothecolumn.Thesteelworkcolumniscoveredinsurfacecorrosion,butattheirbasethecolumnandgussetplatesareseverelycorrodedanddelaminatinginplaces.
6.8.6 Store(vii):
Thetimbergroundfloorinthisareaisinanextremelypoorconditionwithextensiverottenandcollapsedareasofthefloorstructure.
6.8.7 LoadingBay(viii):
Noaccesspossibletothisarea.
6.8.8 Office(ix):
Localareasofthetimberboardedfirstfloorandthesteelbeamsupportshavesufferedasaresultoftheirprolongedwetstateandinplacesthetimberisclosetocollapse.Thereisextensivesurfacecorrosioninthesteelbeams.
6.8.9 Noaccesswaspossibletolookatthesteelframesupportingthelargewatertankoverthecondenserroom.Itseemsverylikelythatthissteelworkisinapoorconditionespeciallywhereitisbuiltintothebrickworkwalls.
6.8.5 TankRoom(1907/1910)(vi):
Thetimberandsteelframedstructuresupportingthefirstfloorhassufferedfromrainwaterpenetrationandtheaggressiveconditionswithintheicemakingenvironmentinasimilarthoughseeminglynotasseverelyasintheoriginaltankrooms6.8.2above.
Thesteelgrillageatgroundfloorlevelissufferingfromextensivesurfacecorrosioninplaces,inparticularatthesupportsoffthereinforcedconcretegroundfloor.Itislikelythesewillbeareasofseverecorrosionanddelaminationofthesteelwork.
ThegroundfloorcontainsthreetrencheswhichwereabouthalffullofwaterduringourvisitinJanuary.Wesuspectthereinforcedconcreteisnotinagoodcondition.
6.8.3 IceStore(iii):
Thesteelstructurehereappearedtobesufferingmuchlessfromrainwaterpenetrationthanin6.8.2above,thoughitislikelythattherewillbesomebeamswhichareseverelycorroded.
6.8.4 OldBoilerHouseandCondenserRoom(iv)and(v):
Thegroundfloorslabsintheseareasappeartobeofreinforcedconcreteandcontainssomeplantbases/plinthsandtrencheswithabasementunderthewestern-mostarea.Theextentofthisbasementisnotknownasitwasnotaccessiblethoughitseemslikelytobeonlyunderthissmallwestern-mostspace.
Corrosion to bottom of Columns in 1907/1910 Tank Room
U/s first floor to Tank Room 1907/1910
Gurretted bases to Columns in 1907/1910 Tank Room
First floor to Ice Store 1900/1901
Ground floor to Tank Room 1907/1910
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7.0Proposals for Remedial Works to the Existing Structure7.1 Ourexperienceofbuildingsofthisageshowsthatinorderfor
themtocopewithchangesovertime,andtocontinuetobeuseable,thentypicallytheyneedanoverhaulevery25yearsorso,withmajoroverhaulsevery50yearsorso.Itisalsoveryimportantthataspartoftheseoverhauls,allthedefectsinthestructurenotcoveredbythenormalmaintenanceofabuildingaredealtwith.Goodbuildingsofthisagecangenerallybekeptgoingalmostindefinitelyifproperlymaintained.
HereattheIceFactoryitseemsthatitshistoricaldevelopmentfollowedalongthistypicalpathforawhile,ie:
• Built1990/1901and1907/1910
• Firstmajoroverhaul1930s
• Secondoverhaul1950s
butthenwiththefishingindustryindeclineitlooksasifthenexttwooverhaulsaround1975andcertainlyin2000didnothappen.
Forthegeneralconditionofthestructureitlooksasiffew,ifany,ofthedefectsinthestructurehavebeenaddressedinthissecondhalfofitslife.
TheaggressiveconditionsgeneratedintheIceFactorymeantthatthebuildingwouldhaveneededmuchmoremaintenancethanotherbuildingsofitsage.
Itisclearthatthebuildinghasnothadanymaintenancecarriedoutformanyyearsandisnowdeterioratingatarapidlyacceleratingrate.
Lifecycle between major services/overhauls for typical traditionally built building
Lifecycle between major services/overhauls for the Ice Factory
Rate of Deterioration
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Thelongerspanpitchedroofsovertheoldboilerhouse,andthetankrooms(1900/1901and1907/1910)generallyappeartobeinalittlebetterconditionthantheothers.Intheseareasthetimberboardinglookstobeinapoorstateinplaces,butelsewhereitmaybepossibletore-usetheboards.Similarly,someofthetimberpurlinslookasiftheywillneedreplacingandotherslookasiftheycanberetained.
Wesuggestthat:
2. Alltheroofcoveringsareremoved(seealsoArchitects’report).
3. Alltimberboardingisremovedandseparatedintothatwhichcanbere-used(say30%)andthatwhichcannot.Theboardschosenforre-usewillneedtobedry,and/ordriedinacontrolledenvironment.
4. Thetimberpurlinsareremoved,andseparatedtothosethatcanbere-used(say50%)andthosewhichcannot.
5. Thesteeltrussescanthenbethoroughlywirebrushedtoremoveallsurfacecorrosionandrepainted.
6. Thenewandretainedpurlinsandboardscanthenbefixedinposition.
7.2.2 RoofStructure:
Whilstsomedetailedinvestigationwillbeappropriateinduecourse,itseemsatthisstagethattheflatroofedareashaveallsufferedfromextensiverainwaterpenetrationoversuchalongperiodoftimethatitseemsverylikelythattheywillallneedtobereplaced,ontopoftheexistingsteelbeams.Thisappliestoallthesteelfillerjoistroofsandthe1950sreinforcedconcreteroofoverthenewcompressorroom.
Wesuggestthewayforwardhereisforthereplacementworkstocommencewithastagedremovaloftherooffinishesandthentheconcretetoexposethesteelfillerjoistsandreinforcement.Theconditionofthejoistsandreinforcementcanbeassessedastheyareexposedandiffoundtobeinabetterconditiontothatcurrentlyexpectedthenitmaybepossibletoretainsomeofthesteeljoistsandmaybepatchrepairther.c.slab.Atthisstage,however,itwouldbeprudenttoallowforitalltobereplaced.
Theconditionofthepitchedroofstructuresvariesconsiderably.Thesmallpitchedroofovertheoriginal1900/1901office,andthemultipitchedroofoverthestoreinthe1907/1910buildingappeartobeintheworstcondition.Atthisstagewesuggestanallowanceismadeforreplacingtheroofstructureovertheofficecompletely.Overthestoreitlookslikelythatthesteelvalleybeamswillneedsomeremedialworkespeciallywheretheyarebuiltintothewallsandthetimbertrussesarelikelytoneedrepairs/loadrebuildingattheirendswheretheyaresupportedoffthevalleybeams.Allboardingandpurlinsarelikelytoneedreplacement.
7.2 Thefollowingsectionoutlinestheapproximatescopeofremedialworksrequiredtotheexistingstructuretoaddresstheobviousproblemsdescribedearlier.
7.2.1 ExternalWalls:
Allthecracksinthebrickworkneedtobemadegoodbycarefullycuttingoutthecrackedbricksandstitchinginnewbrickwork.Wherethecracksextendfullwidththroughthebrickwork,thisneedstobedonefrombothsides(insideandoutside).
Wherethecracksaretheresultofcorrodedsteelworkthecauseofthecracking,ietheexpansionofthesteelworkasitcorrodesanddelaminates,alsoneedstobeaddressed.Thisinvolvescarefullyremovingthebrickworkaroundtheembeddedsteelwork(egbeamend),introducingtemporarysupportstothesteelworkwhereneeded,sothatthesteelworkcanbethoroughlywirebrushedtoremovealllooserust,cleaned,andthenpaintedwithtwocoatsofbituminouspaint,priortomakinggoodthebrickworkaroundthesteelasabove.Insomelocationsthesteelworkmaybefoundtoalsoneedsomerepairandsoacontingencyshouldbeallowedtocoverthistoo.
Wheresteelbeamsarebuiltintotheexternalwalloveropeningssuchastotheloadingbay(viii),allowforthefirstthreecoursesofbrickworkoverthebeamtobecarefullycutouttoallowthebeamtobetreatedandthenreplaced.
Refertodrawingnumbers1568/01/07to08whichillustratesthelikelyapproximateextentofbrickworkrepairsatthisstagerelatedtostructuralremedialworks.RefertotheArchitects’drawingsforallotherworkstotheexternalwalls.
Roof over Ice Store 1900/1901Cracks in brickwork where steel beam is severely corroded
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7.2.3 InternalStructure:
Withtheenvelopeofthebuildingsmadegoodtheinternalstructurewillneedtimetodryouttodeterminetheextentofremedialworks,thoughtoachievethisstateandtotacklesomeoftheobviousdefectswesuggestthefollowingapproach:
(ii) Clearoutallthedebrisetc.
(iii) Removeallrotten/damagedtimberboarding.
(iv) Pumpoutallthewaterfromthetrenchesandundercrofts.
(v) Wheresteelcolumnshavebecomesignificantlyaffectedbycorrosion/delaminationtheseshouldeitherbereplaced,orperhapsencasedinreinforcedconcretetomaintaintheirstructuralfunction.Thisappliestosomeifnotallofthecolumnsintheundercroftbeneaththeoriginal1990/1901tankrooms.
(vi) Thebuildingsthenneedtobewellventilatedtoallowthemtodryout.Thisneedstobedoneinacontrolledandmaintainedwaysothatitisnotonlyeffectivebutalsoavoidsfurtherproblemsbeinggeneratedsuchasdryrotmanifestingitselfinthetimberstructure.
7.3 ContractorsSiteSetUp
AspartoftheseworkstherewillbeasubstantialcostinvolvedintheContactorestablishinghissetuponsiteincludingallthetemporaryworksnecessaryforsafeaccessinordertoclearoutallthedebrisandcarryouttheremedialworks.Thiswillincludeaccessdecksandstairsaswellasprotectivedecksforsafeaccess.
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Dependingontheproposednewusesitmaybepossibletoreplace(eitherallorinpart)theexistingveryheavydutyfloorstructuresinthetankroomswithseveralnewlighterweightfloorstructures.
Intheareaswheretherearenointernalupperfloors,e.g.originalcondenserroom,boilerhouseandthe1907/1910store,itislikelythattheexistingstructure(wallsandcolumns)couldbeusedtosupportoneormaybetwonewfloors.
RefertotypicalsectionC.
8.0Proposed Alterations to the Structure8.1 Atthisstagetherearenospecificalterationsproposedand
NELChaverequestedsomegeneralcommentsonthefeasibilityofcarryingoutalterationsandaddinginnewfloorswithintheexistingbuilding,allbasedontheunderstandingwehaveoftheexistingstructure,describedabove.
Thefollowinggeneralcommentsassumethatallthedefectsintheexistingstructureareaddressedpriortocarryingoutanyalterations.
8.2 Roof:
Theflatroofedareascanprobablybeusedtosupportsomenewlightweightplant.Shouldtheexistingwatertankovertheoriginalcompressorroomberemovedthenthatareaoftheroofshouldbeabletocopewiththeadditionofnewplant/accommodationofasimilarmasstothewatertank.
8.3 Walls:
Thebrickworkwallsaregenerallyrobustandhavebeenusedtosupportveryheavyimposedloadsaspartoftheicemakingprocess.Itseemslikelywiththeicemakingprocessremoved,thattheycouldbeusedtosupportsomesignificantnewimposedloadsfromadditionalfloors.
Itlooksfeasibletobeabletoremovethetravellingcranebeamsandtheirfixingbracketswithoutsignificantlyaffectingtheintegrityofthebrickworkpiers/walls.
8.4 Floors:
Currentlyitseemslikelythatthefloorsinthemaintankroomsdocontributetotheoverallstabilityofthebuildingandthebrickpiers.
Wherethemainfloorbeamsareconnectedtotheexistingbrickworkwithexternalfixingplatesitmakessensetoretainthesefloorstructuresaspartofanynewscheme,thoughinprincipleitwouldbepossibletoremovethemandreplacethemwithnewfloorstructures.
Timbertrusses
Travellingcrane
Travellingcrane
1stfloor
SteelgrillageontopofRCtrenches
Steelbeam
Steelcolumn
IceStore TankRoom
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9.4 Itneedstoberecognisedthatthescopeofremedialworksin(iii)aboveisaimedataddressingtheobviousdefectsinthestructure,itisthenatureofbuildingsthatsomedefectsarehiddenandmayonlybecomeobviouseitherduringtheworksonsite,orindeedlaterinthelifeofthebuilding.
Allremedialworksshouldbedesignedtosympatheticallyrepairorimprovetheexistingstructure,thoughagainitshouldberecognisedthattheseworkscannotbecomparedtonewconstruction,andareaimedatextendingtheusefullifeofthebuildingwhichisindeterminate,andreliesonhowwellitiscaredforinthefuture.Itwouldbeusefultodevelopasimplemonitoringregimeaspartofthedetailedproposalstoassistwiththeassessmentofthesuccessoftheproposalsandasacheckonfuturemovementsofthestructure.
9.5 Aspartofthenextstageoftheworkswerecommendaconservationassessmentismadeofthebuildingsandtheircontentstoassistinthepreparationoftheproposals.
9.3 AsdiscussedwithNELCthisreporthasconsideredthelikelyscopeofremedialworksrequiredtoaddressalltheissuesraisedintheNELCScopeofWork.
AnestimatedcostoftheseworkshavebeenpreparedbyKMCS.
Twofurthercostestimateshavebeenprepared:
i. forworksofalesserscalethanabovejusttoaddressrainwaterpenetrationofthebuilding.
ii. Simplytoenclosethebuildinginasheetedscaffoldtotryandkeeptherainwaterout.
Inverygeneraltermsthelikelyeffectofthethreealternativescostedare:
i. Scaffoldonly:Thiswillslowdowntherateofescalationofthedegradationofthestructure,butshouldbeconsideredasatemporarymeasureonlybeforeproceedingwithmoresubstantialworks.
ii. LesserScaleofWorks:Thiswilladdressthemostobviousdefectsinthestructureandprovideabreathingspacebeforecarryingouttherestoftheworksin(iii)below.
iii. NELCFullScopeofWorks:Thisshouldpreparethebuildinggenerallyforconversionorrefurbishmentonceausehasbeenfound.
9.0Next Stage9.1 Thisreportisaimedatprovidingaveryoutlinescopeofworks
anda‘ballpark’costestimateofthelikelyremedialworksneededtotheexistingbuilding.
9.2 Inordertopreparemoredetailedproposalsforthepurposesofobtainingtendersfortheworkthenwesuggestanenablingcontractisbuiltintotheprogramme.Thisenablingcontractwouldincludesomephysicalopeningupworkstoassistindeterminingtheseverityofdegradationofthestructureandbetterdefinetheextentofremedialworks.Itcouldalsobeusedtocarryouttrialrepairsforagreementwithinterestedparties(e.g.EnglishHeritage)priortocommencingthemainworks.
Theseinvestigationworkswouldinclude:-
• Breakingoutareasoftheflatroofedstructuretorevealtheseverityofcorrosionoftheembeddedsteeljoistsand/orreinforcement.
• RemovalofareasoftherottentimberfloorsintheTankRoomsandIceStorestohelpclarifytheseverityofcorrosionofthesteelstructure.
• Trialpitstoexposethefoundationsandcheckwhetherthebuildingissupportedofftimberpiles,andwhetherthepilesextendabovethecurrentgroundwaterlevel.
• Providingsafeaccesstopreviouslyinaccessibleareasofthebuildings.
• PumpingoutofwaterfromtheundercroftandServiceTrenches.
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10.0Existing Fabric, by Richard Griffiths Architects (RGA)
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11.0Cost Estimate, by KMCS
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Appendices
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Appendix AInformation Received
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Appendix BDrawings by ABA
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Appendix CDrawings by RGA
PreparedbyDavidJohncox,withsectionsfromRichardGriffithsArchitectsbyJohnWoodcock,andfromKCMSbyColinHayward.ReviewedbyMichaelCoombsIssuedFebruary2010
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