Ascot Racecourse had a high-level glass facade pane fail due to Nickel sulphide inclusion, causing it to shatter and requiring it to be replaced.
Ascot is a busy and thriving commercial space that holds functions most weekends. Time was of the essence to ensure the business could continue running without too much disruption.
To address the challenges we were facing, our Director Tom Pickess travelled to Ascot to perform a comprehensive survey of the shattered glass pane in the planar structural facade system. The glass pane was central in the system hanging from two 25.5mm toughened laminate glass fins on planar bolts with a silicone joint to the surround.
Working closely with our client for their requirements, an extensive plan was put into place for the removal and re-install of this unit. This project required a supply & install of a 1180mm x 3400mm pane weighing more than 390kg. The glass specification was 21.5mm clear toughened laminate safety glass with polished edges, heat-soaked, with 12mm/1.5mm SGP interlayer/12mm with 6 countersunk holes.
As agreed with our client, internal and external scaffold was erected. The two-tier decked scaffolding was the best option giving a clearer access to the glass. The scaffold required ladder beams over the top platform mounted around the existing steel beams supporting the roof for the electric hoist /block and tackle to secure too. The scaffold had pull tests carried out along with a 500kg weight test to the electric hoist to confirm all was suitable for the lift. The scaffold was finished off with Monoflex sheeting externally, to help conceal the scaffolding from the everyday ongoings at the racecourse.
With the aid of our own glazing robot, our team of glaziers were on site the day before to take delivery of this 390kg unit. This was to ensure there was no hold up on the day of works and to guarantee an early start.
A DSZ2 glass vacuum sucker pack along with secondary safety straps and guide ropes were attached to the glass to safely remove it via the block and tackle. The glass was passed down through the scaffolding on the electric hoist and landed on waiting supports on the ground floor to then be loaded and taken away. The install of the new pane was carried out with care and attention, using edge protection on the glass, along with guide ropes to lift the glass through the scaffold smoothly. The space the team had to work with was very tight and expert teamwork was key to success. Once installed back into the system, the glass was cleaned, checked over and a clear silicone seal applied to the surround to finish off the installation.
The project was carried out in accordance with the client’s planned schedule with the objective of causing minimal disruption to their trade. This case study demonstrates our commitment to delivering bespoke solutions that exceed our client’s expectations, ensuring lasting value for a commercial property.
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