Corrivo partnered with Valentine Building Services (VBS) to support the successful delivery of a 1,100 m2 over-cladding project at Halifax Glass. By introducing a more efficient, fabrication-led approach, specifically, the pre-punching of galvanised steel components, Corrivo helped reduce installation time by 3 days.
The end result was a faster, safer, and more streamlined project delivered within tight timescales and without disruption to the client’s live manufacturing environment.
About the Client and Project
Valentine Building Services is a well-established contractor specialising in roofing and cladding solutions across industrial and commercial environments. Known for delivering complex projects in demanding conditions, VBS was appointed to undertake a substantial 1,100 m2 over-cladding programme at Halifax Glass, a fully operational glass manufacturing facility.
The project involved upgrading the existing roofing system while the site remained in full operation. This created an added layer of complexity, as all work needed to be carefully planned and executed to avoid interrupting production. In addition to logistical challenges, the scale of the roof area required precise coordination of materials and installation processes to maintain efficiency and ensure progress remained on schedule.
Business Challenges and Objectives
A key requirement of the project was the installation of 360 galvanised top hat sections, each measuring three metres in length and manufactured from 1.6mm material. These components were essential to the structural integrity of the over-cladding system. However, the conventional supply method presented a significant issue. Typically, such sections are delivered without pre-formed fixing points, meaning contractors are required to drill holes manually on-site as installation progresses.
For VBS, this approach created several compounding challenges. Working on a live factory roof meant that time on-site was at a premium, and any process that slowed installation introduced both operational risk and additional cost. Manually drilling hundreds of fixing holes at height is not only labour-intensive but also increases health and safety considerations, particularly in an active industrial setting.
In addition, VBS faced difficulties sourcing the required galvanised top hat sections within an acceptable timeframe. These components are often supplied as part of larger, bundled packages, which can significantly extend lead times. With tight project deadlines and ongoing site activity, VBS needed a solution that would reduce on-site workload, shorten installation times, and ensure materials could be delivered quickly and reliably.
Corrivo’s Solution
Corrivo addressed these challenges by rethinking the role of fabrication in the project. Using its advanced Amada punching technology, Corrivo was able to shift a key portion of the installation process away from site and into the controlled environment of its manufacturing facility.
Rather than supplying standard, unprocessed sections, Corrivo proposed pre-punching all fixing holes during production. This approach required detailed coordination with VBS to ensure hole positions and spacing would align perfectly with on-site requirements. To eliminate any uncertainty, Corrivo produced and supplied initial samples for testing. This allowed the VBS team to trial the components in situ, confirm accuracy, and refine any details before full-scale manufacturing commenced.
Once approved, Corrivo proceeded with the production of all 360 sections, ensuring each piece was manufactured to consistent tolerances and fully prepared for immediate installation upon delivery. Crucially, this entire process was completed within a significantly reduced lead time, overcoming the typical delays associated with sourcing these materials through conventional supply channels.
Results and Benefits
The impact of Corrivo’s solution was felt immediately on site. By removing the need for manual drilling, installation teams were able to work far more efficiently, focusing solely on positioning and fixing the pre-prepared components. This not only accelerated the overall programme by three days, but also reduced the level of physical effort required, improving working conditions for operatives and lowering the likelihood of delays.
The precision achieved through factory-based punching ensured a high degree of consistency across all components, reducing the risk of errors and rework during installation. Just as importantly, the shortened installation time helped minimise disruption to Halifax Glass’s operations, which was a critical factor given the live nature of the facility.
From a commercial perspective, the reduction in labour hours and improved installation speed contributed to greater cost efficiency for VBS, while the reliable, fast-track supply of materials ensured the project remained firmly on schedule. By transferring complexity away from the construction phase and into the manufacturing process, Corrivo enabled a smoother, more predictable delivery from start to finish.
“Corrivo provided excellent customer service from start to finish and really understood the pressures we were working under on this project. Sourcing the galvanised top hat sections within a tight timeframe was already a challenge, and the prospect of drilling hundreds of fixing holes on a live factory roof would have added significant time and complexity to the job.
By pre-punching all 360 sections to our exact requirements and turning them around quickly, Corrivo eliminated a major element of on-site labour and helped us keep the installation programme moving efficiently. The samples they provided upfront gave us complete confidence that everything would align correctly, which was invaluable before committing to full production.
The quality, accuracy, and speed of delivery made a real difference to how smoothly the project ran, particularly in such a sensitive, operational environment. We wouldn’t hesitate to work with Corrivo again and would highly recommend them to others.”