Benteler Automotive Facility Projects

Benteler Automotive Facility Projects: Scope of Works

 

Interkey Contracting was engaged by Benteler Automotive, a leading global supplier to the automotive industry, to deliver a package of critical upgrades and restoration works at their UK manufacturing and logistics site. Operating under live industrial conditions, our scope included a combination of civil engineering, structural alterations, building envelope enhancements, and dilapidation refurbishment to extend asset life and improve operational flow.

​

Key Project Aspects:

​

Concrete Slab Installation (Yard Area)​: We delivered a high-strength external concrete slab system designed for heavy vehicle usage and yard-level rationalisation. 

​

• Excavation with precision level reduction

• Off-site disposal of surplus spoil

• Installation of a 1200-gauge polythene weed membrane

• Placement of a 150mm thick C35 reinforced concrete slab with a durable brushed surface finish

• Integration of expansion joints to manage thermal movement and prevent long-term cracking​

​

Door Relocation & Structural Steelwork​: To support internal reconfiguration, we relocated a series of key access doors.

​

• Design, fabrication, and installation of new structural steel supports to accommodate a roller shutter and adjacent pedestrian door

• Safe isolation and disconnection of electrical services to the existing door, including emergency lighting, control panels, and power feeds

• Recommissioning all systems at the new door location, ensuring full functionality and compliance with fire exit standards​

 

Cladding Installation at New Door Zones​: Following door relocation, we installed a tailored cladding solution.

​

• Composite insulated wall panels, designed to match existing façades

• Bespoke flashing, weatherproofing trims, and sealing details

• Installation performed in line with BS EN 1090 standards, ensuring durability, thermal continuity, and aesthetic consistency​

 

New Canopy Installation:​ To create a new covered working area and improve vehicle loading efficiency, we converted an existing façade into an open lean-to canopy.

​

• Removal of existing cladding and redundant structural elements at the former roller door zone

• Reuse and adaptation of the steel frame to support the new configuration

• Creation of a weather-protected access zone suitable for operational activities during inclement weather

 

Dilapidation Repairs & Internal Refurbishment​: A comprehensive programme of dilapidation and remedial works was delivered across the site to restore building condition and meet lease return standards.

​

• Filling and patching of wall cracks and surface imperfections

• Damp treatment, stain blocking, and sealing to walls and window sills

• Repainting of internal surfaces across welfare and operational zones: entrances, corridors, toilets, locker rooms, canteens, and offices

• Gloss refinishing of woodwork and doors

• High-level access using MEWPs (Mobile Elevated Work Platforms) for safe completion of elevated works

• Full surface cleaning, including internal walls, ceilings, and external cladding, to deliver a professionally presented and ready-to-use facility

​

Interkey Contracting delivered all works to a strict programme within a live manufacturing environment, coordinating closely with Benteler’s site operations team. Our ability to self-deliver across civils, steelwork, envelope, and internal refurbishment disciplines enabled a seamless, end-to-end solution with minimal disruption to production.

​

By combining precision engineering with a high-spec finish, we helped Benteler extend the lifecycle of their facility, improve operational access, and meet corporate asset standards for health, safety, and presentation.

​