Andrew McClusky, BEP Surface Technologies managing director (left) and Steve Howard, founder and directorGreater Manchester-based
BEP Surface Technologies, a leading provider of surface finishing solutions, has completed a four-month long £500,000 factory refurbishment to drive growth and innovation. The large-scale and complex project overhauled and modernised BEP’s electroplating operations and enhanced its sustainability credentials, operational efficiency and safety, while at the same time future-proofing the facility for decades. It involved the removal of large electroplating tanks, with capacities ranging from 4,500 to 15,000 litres, along with all ancillary equipment, including buzz bars, local exhaust ventilation (LEVs), cooling coils, and heating elements.
Over 31,500 litres of chemical solutions, including sulphuric and caustic substances classified as hazardous waste, were extracted and safely disposed of, adhering to strict environmental regulations. The company retained the chrome tank solutions for re-use, further aligning with its sustainability objectives. Subsequent phases involved extensive renovation to the pit floor and walls, which was then re-lined with a robust, chemical-resistant coating. The project concluded with the installation of four newly designed tanks, establishing a foundation for decades of enhanced productivity and reduced maintenance.
BEP electroplates parts for various industries, including nuclear, packaging, manufacturing, defence, and aerospace. As such, it specialises in precision turning and cylindrical grinding of a wide range of industrial components, from pump shafts to chill rolls, handling weights from a few kilograms up to 20 tonnes. Innovative approaches to pit refurbishment continue to be a cornerstone of BEP’s legacy. The company’s last refit was almost 30 years ago.
BEP collaborated with key contractors, including CSG, a prominent UK waste management firm, for cleaning operations; Arc Fabrications Ltd, for tank fabrication and installation; and Coral Eastern, for concrete and lining services, to ensure the success of the ambitious project.
‘Black Swan Event’Andrew McCluskey, BEP Surface Technologies’ managing director, said: “The new infrastructure streamlines processes, minimising downtime and enhancing productivity. This project is what I refer to as our ‘Black Swan Event’, with an anticipated operational lifespan spanning several decades. We undertook this refurbishment to utilise our expertise and ensure every detail aligned with our operational needs.
“Some might argue that third parties are better suited to complete such projects, but we know our factory intimately, and dedicating all our resources to this initiative made perfect sense. By investing in durable materials and thoughtful design, we have secured a facility that will endure long beyond my tenure at the company. This refurbishment showcases BEP’s commitment to innovation and sustainability, enhancing efficiency and reinforcing our environmental responsibility.”
Lewis Brierley (pictured left in the refurbished pit) who led the project and is part of BEP's expert chemical team, said: “This project required a balance of technical precision and sustainability. By collaborating with industry specialists and utilising advanced materials, we have extended the operational life of critical infrastructure by decades. This refurbishment is not merely an upgrade but a future-proof solution for both environmental and economic efficiency.”
He further explained that he drew from the experience of Steve Howard, BEP’s founder and director, who had commissioned the first pit over 40 years ago. He continued: “Working with Steve, the original architect of the pit, has been invaluable. His decision to exclude limestone from the concrete over 40 years ago demonstrated remarkable foresight and has contributed to the pit's longevity. Drawing on his extensive knowledge during this refurbishment has been a tremendous learning experience, and we are implementing modern solutions to ensure the facility serves us well.”
A critical aspect of the refurbishment was restoring and reinforcing the concrete pit to restore its structural integrity. BEP opted for a high-performance fibreglass-reinforced epoxy resin lining to enhance durability and chemical resistance, which was rigorously tested to withstand harsh conditions. Furthermore, new titanium-lined tanks with upgraded 3mm liners replaced the previous 1mm versions, improving durability and reducing maintenance requirements.
The project concluded with the re-installation of ‘state of the art’ ancillary components to improve operational efficiency and safety, including a redesigned operator flooring system that provides 360deg access.
This refurbishment significantly enhances sustainability by reducing environmental impact by retaining and storing chrome solutions instead of disposal. The revamped facility now features improved flooring and equipment accessibility, ensuring a safer working environment for operators. Advanced materials, such as the Belzona 4341, are used. This durable, two-part epoxy barrier coating is optimised to resist hot inorganic acids such as sulphuric and hydrochloric acid up to 90°C.