
Case Study
Case Study: External Façade Tile Replacement in Hospital Car Park
Overview:
The external façade of a hospital car park, constructed from pre-cast concrete panels finished with terracotta tiles, had become a significant safety concern. Tile adhesion failures were not only unsightly but also posed a serious risk to public safety. Our task was to replace the damaged tiles while preserving the aesthetic integrity of the building and ensuring a robust, long-lasting solution.
Challenges:
This complex project presented several challenges:
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Tile Sourcing: Extensive research was required to identify the original tile manufacturer. This led to sourcing a German manufacturer to reproduce the tiles to a perfect match, ensuring aesthetic continuity.
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Adhesion Solutions: The size and weight of the tiles made finding a reliable adhesion method critical. After off-site testing with building material manufacturer Sika, we developed a solution that ensured the tiles would remain securely fixed in various conditions.
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Public Safety: Given the high foot traffic in and around the hospital, safety was paramount. Comprehensive pedestrian and traffic management plans were implemented to ensure public safety throughout the project.
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Our Solution
Accessing the façade required innovative solutions to reach every area safely and efficiently.
These included:
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Fixed scaffolding around the building façade.
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Smaller portable tower scaffolds for manoeuvrability.
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Truck-mounted platforms to access difficult-to-reach areas.
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The Process:
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Tile Removal: Damaged tiles were carefully removed by cutting them into manageable pieces, ensuring safety and minimizing disruption.
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Surface Preparation: The exposed concrete panels were prepared to create a uniform, flat surface for the new tiles. This included concrete repairs using Sika Monotop products to address areas of spalling and create a strong base.
Tile Installation: The reproduced terracotta tiles were installed using the tested Sika adhesive system, ensuring durability and a secure bond.
Safety Measures: Every step of the process adhered to strict safety protocols, including daily site inspections and proactive risk management.

The Progress



The Finished Project
The Results
Despite the complexities of the project, the work was completed on time and on budget, meeting the client’s expectations. Daily communication ensured transparency and allowed for any challenges to be addressed promptly.
The car park façade now boasts a fully restored appearance, with the terracotta tiles securely adhered and structurally sound. The result is a durable, visually cohesive finish that enhances safety and aesthetic appeal.
Why Choose Us?
This project highlights our ability to manage complex, high-stakes challenges with precision and expertise. From sourcing bespoke materials to ensuring public safety, we deliver tailored solutions that exceed client expectations.