AMMONIA
PIPEWORK
RE-INSULATION
Sector: Dawn Meats
Location: Carrols Cross
Industry: Meat Processing
Company Size: Large-Scale food manufacturing operation
System Type: Ammonia Pipework
Scope of Works: Improving Thermal Efficiency, Safety, and Appearance in a Live Production Environment
Dawn Meats Carrolls Cross operates a high-demand production facility reliant on ammonia pipework to maintain strict temperature control. The integrity of this system is critical to both operational efficiency and safety.
The Challenge​
Over time, the existing insulation on the ammonia pipework deteriorated significantly. Heat and cold were passing through the insulation rather than being retained, leading to inefficiencies and increased operational costs. In addition to the performance issues, the insulation had become untidy and degraded, negatively impacting the overall condition of the roof void area.
The project presented several key challenges:​
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The pipework was live and operational.
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Uninsulated pipework could not be left exposed for more than 12 hours due to the risk of ice build-up, corrosion, and potential ammonia leakage.
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All work needed to be completed within a tight 12-day window to minimize disruption.​​​
Project Objectives
The client’s primary objective was to:
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Reduce ongoing operational costs by upgrading the insulation system.
Success was defined as:
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Completion within the agreed timeframe
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Delivery within budget
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A visibly improved finish and overall aesthetic of the pipework
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Maintaining safety standards throughout a live ammonia environment
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Execution quality, safety, and program adherence were some of the critical measures of success.
Our Solution & Approach​
Our team was engaged to fully remove and replace the existing insulation while the system remained live. To mitigate risk and downtime, we made the key decision to deploy a larger, highly experienced team of eight insulators, allowing work to be completed efficiently without leaving pipework exposed beyond safe limits.
​​Delivery & Execution​
Work was carried out in controlled daily phases.
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On average, the team completed 10–20 meters of pipework per day, following a consistent process:
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Strip old insulation.
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Clean pipework and roof void area
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Apply Denzo tape.
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Install aluminium cladding.
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Foam in place injection insulation.
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Seal, clean, and finish the cladding.
​​Results & Impact​
While quantitative energy savings were not formally measured, the project delivered clear operational and visual improvements.
Outcomes Included:
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Significantly improved insulation performance
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A clean, well-organised roof void, compared to the previously deteriorated condition.
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A high-quality, uniform finish to all pipework
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Completion on time and within budget
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Zero rework required following final inspection
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Before-and-after images below clearly demonstrate the transformation achieved.​​​
​Client Communication​
Clear communication was a priority throughout the project. A dedicated WhatsApp group was used to:
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Provide daily progress updates.
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Share photographs of completed sections.
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Outline targets for the following day.
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This ensured full transparency and allowed the client to track progress in real time.
Safety Considerations
Stripping insulation from live ammonia pipework carries inherent risk. The team worked with extreme caution, using controlled methods and maintaining exceptional housekeeping standards to ensure a safe working environment at all times.
Why This Matters​
This project demonstrates our ability to:
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Work safely on live ammonia systems.
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Deliver high-quality insulation solutions under tight time constraints.
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Minimise operational risk and downtime.
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Maintain exceptional communication and site standards in complex industrial environments.
Client feedback summary
provided at project close-out.
This project was successfully delivered within a live and restricted operational environment, with strong emphasis placed on quality, safety, and communication throughout.
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The works concluded with a fault-free handover and a final inspection that required no remedial actions. The client acknowledged the high standard of workmanship, proactive communication, and overall professionalism demonstrated on site, and expressed confidence in recommending our team for future works.
Get in Touch
If your facility is experiencing insulation degradation, rising energy costs, or requires work in a live refrigeration environment, we would be happy to discuss how we can help. Get in touch to see how we can deliver the same results for your operation.