GKN Aerospace, Avonmouth

In 2024, TRS was appointed to undertake the re-roofing of a business critical facility for GKN Aerospace at their Avonmouth site in Bristol. GKN Aerospace is a global technology leader in the aerospace industry, and the building forms an important part of their South West operations.

The existing roof had reached the point where refurbishment was required to guarantee the long term weathertightness of the building and protect the sensitive aerospace operations continuing beneath it. The existing metal roof and rainwater goods had suffered the typical effects of age and weather exposure on a large industrial envelope of this scale, and as a live aerospace facility the works demanded careful sequencing, strict site control and thorough coordination with GKN's operations team.

TRS installed a new insulated over-cladding system directly over the existing roof, providing an upgraded thermal and weathertight envelope without the disruption, cost and downtime of a full strip and replace. Detailing was carried out around every roof penetration to secure the building for the long term.

Alongside the over-cladding, the ageing rainwater system was fully replaced and new flashings were installed around every existing vent and upstand, delivering a completely secure and waterproof building envelope for the client.

As Principal Contractor, our scope of works included:

• Full site setup and welfare, coordinated with a live aerospace facility
• Tower crane hoisting for safe material movement across a 9,000 m² roof
• Installation of a new insulated over-cladding system over the existing roof
• Renewal of the perimeter gutter system
• New flashings around existing vents, penetrations and upstands
• Detailing at all abutments and edge conditions
• Full project management and health & safety coordination under CDM 2015

The building remained fully operational throughout the works. Deliveries, lifts and any noisy activities were sequenced around GKN's production schedule to protect aerospace operations continuing directly beneath the roof, and the refurbishment was phased across the roof over the 18-week programme to maintain progress while minimising impact on day to day operations.

Working on a live aerospace facility in Bristol required strict site management and a comprehensive access strategy. Perimeter edge protection, MEWP access and a dedicated tower crane were used to move materials safely and efficiently across the 9,000 m² roof. RAMS were briefed prior to each phase and coordinated with GKN's onsite team. Every phase was signed off with photographic QA, and the installation was inspected in line with the manufacturer's requirements for the 25-year insurance-backed guarantee.

TRS completed the works within the agreed 18-week programme and without issue, leaving the new roof in perfect condition. The finished installation delivers a completely secure and waterproof envelope, protecting GKN Aerospace's Bristol facility and the critical operations it supports for many years to come.

On completion, a 25-year single point insurance-backed guarantee was issued to GKN Aerospace, providing long-term assurance for the whole system.