The four-month project involved the removal of large electroplating tanks, with capacities ranging from 4,500 to 15,000 litres, along with all ancillary equipment, including buzz bars, local exhaust ventilation (LEVs), cooling coils and heating elements.
More than 31,500 litres of chemical solutions, including sulphuric and caustic substances classified as hazardous waste, were extracted and safely disposed of, adhering to strict environmental regulations. The company retained the chrome tank solutions for reuse.
Subsequent phases involved renovation to the pit floor and walls, which was then relined with a chemical-resistant coating. The project concluded with the installation of four newly designed tanks.
BEP electroplates components for various industries, including nuclear, packaging, manufacturing, defence, and aerospace. As such, it specialises in precision turning and cylindrical grinding of a range of industrial components, from pump shafts to chill rolls, handling weights from a few kilos to 20 tonnes.
BEP collaborated with key contractors, including CSG, a UK waste management firm, for cleaning operations; Arc Fabrications, for tank fabrication and installation; and Coral Eastern, for concrete and lining services, to ensure the success of the project. This refurbishment modernised BEP’s facilities while ensuring compliance with environmental regulations and enhancing long-term operational reliability.
Andrew McCluskey, managing director at BEP Surface Technologies, said: “The new infrastructure streamlines processes, minimising downtime and enhancing productivity. This project is what I refer to as the ‘Black Swan Event,’ with an anticipated operational lifespan spanning several decades. We undertook this refurbishment to utilise our expertise and ensure every detail aligned with our operational needs. Some might argue that third parties are better suited to complete such projects, but we know our factory intimately, and dedicating all our resources to this initiative made perfect sense. By investing in durable materials and thoughtful design, we have secured a facility that will endure long beyond my tenure at the company. This refurbishment showcases BEP’s commitment to innovation and sustainability, enhancing efficiency and reinforcing our environmental responsibility.”
Lewis Brierley, 26, who led the project and is part of BEP's expert chemical team, stated: "This project required a balance of technical precision and sustainability. By collaborating with industry specialists and utilising advanced materials, we have extended the operational life of critical infrastructure by decades. This refurbishment is not merely an upgrade but a future-proof solution for both environmental and economic efficiency."
He further explained that he drew from the experience of BEP’s founder and director, Steve Howard, who had commissioned the first pit over 40 years ago.
“Working with Steve, the original architect of the pit, has been invaluable. His decision to exclude limestone from the concrete over forty years ago demonstrated remarkable foresight and has contributed to the pit's longevity. Drawing on his extensive knowledge during this refurbishment has been a tremendous learning experience, and we are implementing modern solutions to ensure the facility serves us well,” added Lewis.
A critical aspect of the refurbishment was restoring and reinforcing the concrete pit to restore its structural integrity. BEP opted for a fibreglass-reinforced epoxy resin lining to enhance durability and chemical resistance, which was tested to withstand harsh conditions. New titanium-lined tanks with upgraded three-millimetre liners replaced the previous one-millimetre versions, improving durability and reducing maintenance requirements.
The project concluded with the reinstallation of ancillary components to improve operational efficiency and safety, including a redesigned operator flooring system that provides 360-degree access.
This refurbishment enhances sustainability by reducing environmental impact by retaining and storing chrome solutions instead of disposal. The revamped facility now features improved flooring and equipment accessibility, ensuring a safer working environment for operators. Advanced materials, such as the Belzona 4341, are used. This durable, two-part epoxy barrier coating is optimised to resist hot inorganic acids such as sulphuric and hydrochloric acid up to 90°C (194°F).
PIC CA: LtoR Andrew McClusky, managing director, BEP Surface Technologies and Steve Howard, founder and director, BEP Surface Technologies.jpeg
