“We engaged ReviveLogix to handle the structural element of this project and they delivered exactly what we needed. They sweat the small details and communicated effectively, which resulted in seamless execution of the agreed site programme. Rapid PVCU Systems are pleased with the final product and that we are able to minimise disruption to their production. We look forward to working with ReviveLogix again on other projects.”
Luke Crowther, Crowclad Roofing Ltd
When Rapid PVCU Systems found their production area increasingly restricted by an undersized door opening, they turned to Crowclad Roofing, who brought in ReviveLogix to handle the structural side of the project. The result was a wider, safer opening delivered without compromising the building’s structural integrity — and without stopping production.
The Challenge
Rapid PVCU Systems needed a 7-metre clear door opening to allow stillages to move safely and efficiently in and out of a key production area. The existing building had been constructed on 6-metre bay centres, which limited the original opening to roughly 5.5 metres. That restriction was causing real operational problems: the door was regularly damaged, and moving materials through the gap was slowing production down.
Simply fitting a bigger door wasn’t an option. The building itself needed to be structurally altered to create the required clear opening, all while keeping the existing frame stable. The complication that made this a genuinely difficult job: reaching a 7-metre clear span meant removing one of the building’s main portal columns — which meant redesigning how the loads around that opening were carried and transferred.
The Solution
ReviveLogix’s solution centred on removing one of the main portal columns to achieve the required 7-metre clear door opening, while introducing new bracing and a replacement column to maintain structural integrity. The new column was designed and fabricated with rail cleats aligned to the existing cladding rails, minimising the need for intrusive site alterations and keeping installation clean and efficient.
A new transfer beam was installed in two sections. The splice connection was a critical part of the design, incorporating a pre-set with friction grip bolts to help mitigate deflection once the existing column was removed. Once the transfer beam and strengthening works were complete, the existing column was cut away and new door frame steelwork went in. ReviveLogix also cut away the existing blockwork wall up to the face of the new door post, allowing Crowclad Roofing to complete the new trims and flashings.
By day three, the main structural works and blockwork alterations were complete. On day four, the new sectional door was installed — giving the client their required clear opening on a four-day programme.
Before & After
The Outcome
- 7-metre clear opening achieved by removing a main portal column
- Structural redesign to safely transfer loads around the new opening
- New transfer beam installed in two sections with a splice connection
- Production continuity maintained throughout the works
- Full works completed over a four-day programme
The wider opening gave Rapid PVCU Systems easier access, reduced door damage, improved material movement, and uninterrupted production throughout the works.