Barons Quay – Glass Replacement & Remedial Works
Overview
Barons Quay, a large retail and leisure development completed in 2014–2015, began experiencing significant issues with double glazed units spontaneously shattering after installation. Although Bennett Architectural did not complete the original façade works, we were brought in as a specialist contractor to investigate the failures and provide a safe, reliable, and long term solution.
Our remit included the removal and replacement of defective units across the development, many of which were extremely large and required complex handling and installation methods.
Location: Barons Quay, Northwich
Original Development: 2014–2015 (installed by others)
Bennett Architectural Involvement: Remedial glazing works
Scope: Replacement of failed double glazed units
The Challenge
The client reported multiple instances of glazing failure, with double glazed units breaking or shattering due to issues from original manufacture and installation.
Key challenges included:
- Large unit sizes — averaging around 8m² each, weighing approximately 350kg per unit
- Difficult access across a busy retail development
- Need for crane assisted installation
- Requirement to work at night to avoid disruption to the public and ensure safety
- Operations on an active, high-footfall site, creating logistical and safety constraints
These complexities required a carefully planned approach to ensure safe removal, transport, and installation of the oversized units.
Our Approach
Bennett Architectural carried out a comprehensive and controlled replacement programme tailored to the constraints of the site.
1. Detailed Assessment
We inspected the affected glazing units and surrounding frame conditions to confirm the extent of failures and identify the safest method of removal.
2. Precision Crane Operations
Due to the size and weight of the units:
- A crane was used to safely remove and install each pane
- Lifting plans and method statements were developed to meet safety and engineering standards
- Night‑time operations were scheduled to ensure the site remained clear and accessible
3. Controlled Night Works
To minimise disruption, all works were carried out at night when the development was quiet.
This approach ensured:
- Greater operational space for crane manoeuvring
- Increased public safety
- Quicker, more efficient installation windows
4. Replacement of 28 Glass Units
In total, 28 double glazed units were replaced across the complex.
Each was:
- Carefully removed
- Safely disposed of
- Replaced with high quality, compliant glazing
- Installed using specialist lifting equipment and experienced façade operatives
Outcome
Through our work at Barons Quay, we achieved:
- Full replacement of all failed glazing units
- Significant improvements to building safety and performance
- A safer environment for visitors, tenants, and site operators
- A durable, long term solution to glazing failures from the original installation
- Smooth project delivery with zero disruption to daytime operations
The client now benefits from reliable, professionally installed glazing and the assurance that all units meet current performance and safety standards.