
Case Study
Location: Washford Industrial Estate, Claybrook Drive
Property: Manufacturing Complex
Industry: Industrial
Contract Awarded to: RiskFire
Type of Contract: Fire Doors
Project Duration: 8-months
Project Overview & Scope
RiskFire was appointed as Principal Contractor to deliver a comprehensive programme of fire door remedial works and fire door replacements at Gardner Denver’s manufacturing complex in Redditch. The scope included the replacement of fire door sets and remediation of existing doors to achieve compliance with current fire safety regulations. Works were carried out within a live manufacturing environment, requiring careful planning to maintain operational continuity while reducing fire risk across the site.
Project Controls & Documentation Provided
All works were managed in line with the client’s safety-first policies and extensive health and safety requirements. Fire door inspection records, remediation details, and replacement certification were provided on completion, confirming compliance with UK fire safety legislation and BM TRADA–approved repair methodologies where applicable.
Challenges & Solutions
Delivering the project within a live manufacturing complex presented significant challenges, including strict health and safety controls, ongoing production activities, and complex access arrangements. The site also required a phased fire door risk reduction strategy to prioritise higher-risk areas while maintaining operational flow. Additionally, many door openings featured unique sizes and configurations, preventing the use of standard door sets. RiskFire addressed these challenges by fully aligning with the client’s PPE and safety protocols and embedding a safety-first culture throughout the project. A bespoke, phased risk reduction programme was developed and implemented, allowing critical areas to be addressed first while minimising disruption. Close liaison with manufacturers ensured that all replacement fire doors were bespoke, high-quality, and suitable for the specific site conditions. Temporary diversion routes, physical barriers, and segregated work zones were introduced to maintain safe movement around active work areas.

Outcome & Outputs Achieved
The project was successfully delivered on schedule and within budget, achieving full compliance with UK fire safety regulations from a fire door perspective. Fire door replacements ranging from FD30 to FD120 were installed, alongside remedial works to existing doors carried out in accordance with BM TRADA–approved repair techniques. The phased delivery approach, combined with strong health and safety management, resulted in a significantly improved fire safety profile across the manufacturing complex while allowing the site to remain fully operational throughout the works.












