CLADDING CLEANING & EXTERNAL RESTORATION
Energizer Batteries - Ebbw Vale, South Wales, NP23
Client's Challenge
Energiser Batteries required a specialist cladding cleaning and restoration programme at their Ebbw Vale manufacturing facility following long-term environmental exposure and coating failure.
The external steel cladding had deteriorated significantly, with widespread paint flaking, algae growth, surface staining and visible corrosion affecting both cladding panels and security window grills. In addition to negatively impacting the visual presentation of the site, the deterioration posed a long-term asset risk if left untreated.
The client required a restoration-led solution capable of:
• Safely removing failing coatings
• Treating corrosion without damaging the substrate
• Preparing metalwork for full recoating
• Delivering a colour-matched finish
• Operating safely within a live industrial environment
APT ICC were appointed due to their experience delivering cost-effective refurbishment solutions that avoid unnecessary replacement while achieving a high-quality, durable finish.
Assessment & Planning
APT ICC carried out a full externalsurvey of the building envelope to assess the condition of the cladding and associated metalwork.
The assessment focused on:
• Severity of paint failure across elevations
• Extent of algae contamination and environmental staining
• Areas of active corrosion requiring stabilisation
• Suitability of blast cleaning versus wet cleaning methods
• Colour matching requirements for final repainting
• Safe access planning for high-level areas
Multiple restoration options were presented to the client, including repair led refurbishment rather than wholesale cladding replacement, delivering significant cost savings while meeting presentation and longevity requirements.
Methodology
The restoration works were delivered using a structured, refurbishment-led approach:
1. Initial coating removal and surface preparation
Loose and defective coatings were removed using controlled pressure washing and wet blasting methods to expose sound substrates.
2. Low-pressure soda blasting
Soda blasting was used selectively at low pressure to remove remaining paint and corrosion from cladding panels and metal security grills without damaging the steel substrate.
3. Corrosion treatment and priming
Prepared metal surfaces were stabilised and primed to prevent further corrosion and ensure long-term coating performance.
4. Colour-matched cladding repainting
Cladding and metalwork were repainted using Pantone colour-matched coatings to restore a consistent and professional exterior finish.
External ground and drainage works
Pathways, hard-standing areas and surrounding surfaces were cleaned and treated for algae growth. Gutter and roof valley clearance was completed as an
additional client request.
Site Access & Logistics
Equipment:
• Oscillating pressure washing systems
• Soda blasting equipment with vortex blasting head
• High-level lift access equipment
• Commercial painting and coating application systems
Chemicals:
• Algae Free – external algae treatment for cladding and hard-standing areas
The Results
• Flaking coatings fully removed and surfaces stabilised
• Corrosion treated without substrate damage
• Steel cladding restored with colour-matched repainting
• External walkways and hard-standing areas cleaned and made safer
• Gutter and roof drainage routes cleared
• Significant cost savings achieved through refurbishment rather than replacement
The project transformed the appearance of the Ebbw Vale facility, upgrading it from a visibly deteriorated asset to a clean, professional industrial site suitable for staff, visitors and client engagement.
