PROJECT VALUE: £5,000,000

DURATION:  16 weeks

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Emchia Asbestos Solutions Ltd were appointed to deliver asbestos removal works at Ford Motor Company’s Daventry site in August 2024. Spanning a 16-week programme, the project saw up to 80 operatives working under the Emchia banner to safely remove and decontaminate widespread asbestos cement debris throughout the expansive warehouse buildings.
 

Works delivered
The scope of works included the thorough decontamination of roof trusses, purlins, storage racking, lighting conduits and floor areas within the warehouse. Emchia established controlled respirator zones, with physical barriers, warning signage, and a dedicated waste route to safeguard operatives and prevent cross-contamination. Stored items were carefully removed, labelled, cleaned using H-type vacuums, wet suppression and tack-rag wiping, before being reinstated in their original positions — a critical requirement for Ford to maintain continuity of operations.
 

Safe access to high-level structures was achieved through the use of scissor lifts and cherry pickers, operated by trained and competent personnel, with banksmen in place to manage movements and maintain exclusion zones. Strict controls were also implemented to mitigate the risks of live electrics within the work area, supported by additional task lighting. Rigorous housekeeping practices minimised slips, trips and manual handling risks, while daily checks, air monitoring, and supervisor inspections ensured safety and compliance at every stage.
 

All asbestos waste was securely double-bagged, labelled, and transferred along designated routes to Emchia’s waste vehicle before being removed from site by a licensed carrier. Independent UKAS-accredited analysts, along with Ford’s in-house H&S team, inspected and signed off each phase of work, ensuring complete compliance and client assurance.
 

Challenges faced and our response to overcome them

One of the major challenges on this project was the scale of works, with up to 80 operatives working simultaneously across a live industrial environment. Careful planning and phased sequencing were essential to keep the programme on track while maintaining the highest safety standards. Live electrical systems within the warehouse added complexity, requiring enhanced task lighting, strict exclusion zones, and constant supervisor oversight to mitigate risks. High-level decontamination of roof trusses and purlins also presented access challenges, which we overcame through the safe use of scissor lifts and cherry pickers operated by trained MEWP drivers. In addition, Ford required critical stock items to be cleaned and reinstated in their original locations to maintain operational continuity — a task managed through meticulous labelling, tracking, and coordination with the client’s in-house team. Through robust planning, clear communication, and the support of our experienced workforce and supply chain, Emchia successfully overcame these challenges to deliver the project safely, efficiently, and ahead of expectations.