Client: Confidential

Services: Health & Safety Consultancy, CDM Advisory

Location: Germany

Overview

Gleave Partnership provided embedded Health & Safety consultancy services on a major industrial retrofit and expansion programme in Germany. The project involved the delivery of more than 55,000m² of retrofit works within a live operational environment, contributing to the expansion of the facility to approximately 245,000m² of operational space.

Working alongside client, contractor and stakeholder teams, Gleave supported the safe delivery of a highly complex programme involving multiple concurrent work fronts, extensive structural works and the implementation of a pioneering multi-storey robotics environment.

Key Project Elements

• Full internal strip-out and refurbishment works
• Delivery of a multi-storey robotics retrofit environment, the first of its kind in the region
• Simultaneous delivery across multiple live operational zones

Project Challenge

The project was delivered within a live operational environment, requiring extensive retrofit works and a significant facility expansion while maintaining safe operations across multiple active construction zones.

At peak delivery, more than 300 operatives were working across coordinated day and night shifts, creating a complex Health & Safety landscape involving multiple contractors, overlapping work fronts and evolving programme requirements. The introduction of a multi-storey robotics retrofit environment added further complexity, requiring careful coordination of high-risk activities, contractor interfaces and operational stakeholders.

Gleave’s Role

Gleave provided embedded Health & Safety consultancy throughout the project lifecycle, supporting both day and night operations.

Working closely with contractor and client teams, Gleave delivered:

• On-site Health & Safety management and assurance
• Contractor coordination and compliance monitoring
• Oversight of safe systems of work and high-risk activities
• Interface management across multiple active work zones
• Client liaison, inductions and visitor coordination
• Continuous risk monitoring and proactive site inspections

Key Contributions

• Continuous Health & Safety coverage across day and night operations
• Coordination of multiple concurrent work streams within live environments
• Active monitoring of contractor compliance and safe delivery practices
• Facilitation of regular client visits and stakeholder engagement
• Proactive identification, escalation and management of site risks
• Promotion of a strong, visible safety culture across all contractors

Project Impact

The programme was successfully delivered within a highly complex live operational environment while maintaining consistently high Health & Safety standards throughout.

Key outcomes included:

• Over 55,000m² of retrofit works delivered
• Expansion to approximately 245,000m² of operational space
• Safe coordination of 300+ operatives across day and night shifts
• Support of 20+ client visits per week during peak activity
• Successful delivery across multiple live work zones
• Continuous site coverage provided by three dedicated Health & Safety consultants

Gleave’s embedded support approach enabled safe programme delivery, effective contractor coordination and strong stakeholder confidence throughout the project lifecycle.

Related Services

• Principal Contractor Support

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