How refurbishment works
Every building is manufactured inside our dedicated York facility using a proven, quality-controlled refurbishment process. Only the original structural steel frame is retained, everything else is brand new.
1. Asset selection
Choosing the correct units
Once the project is agreed, we select the modular assets from our existing stock at our York facility.
Where a customer’s existing modular building is being refurbished, we will arrange for the units to be transported to our York facility in line with the agreed programme.
2. Strip back
Returning to the structural steel frame
Each module is brought into our factory and completely stripped back to its original steel structure by removing:
- All internal layouts
- Mechanical, plumbing and electrical systems
- Doors, windows and glazing
- Internal and external wall panels
- Existing floor build-ups
- Existing roof build where the build has a roof membrane / blanket system
The only original components retained are the structural steel frame.
By removing everything else, we eliminate hidden damage, trapped moisture and legacy defects, ensuring nothing compromises the new building.
3. Waste recycling
Zero waste to landfill
All removed materials are carefully segregated at source inside our factory into designated bins. This waste is deposited into large skips located within our roller crusher system.
We work in partnership with Yorwaste, a local waste management specialist, to compact waste and ensure materials are recycled or repurposed wherever possible.
This supports our circular economy approach and significantly reduces environmental impact.
4. Inspection & preparation
Structural verification and protection
Once stripped, each steel frame undergoes a detailed inspection process.
Our factory team and an independent Structural Engineer review:
- Welds
- Joints
- Bolted connections
- Floor and roof joists
- Steel side beams
Any damaged elements are removed and replaced with brand new steel elements.
The Structural Engineer then:
- Recalculates the structure based on the new building purpose and intended location
- Confirms structural stability
- Provides formal sign-off
5. Manufacture
A brand-new building on a reused frame
Once approved, we manufacture a completely new building using brand-new, high-quality materials.
Stage 1 – floor construction
A new, fully insulated and regulation-compliant floor is installed to eliminate cold bridging.
Stage 2 – external envelope
New external walls are fitted using our tested 60-minute fire-rated construction system. Fire boarding is added to ceilings.
Stage 3 – internal fit-out
Internal partitions are installed and first-fix mechanical and electrical services are completed.
Stage 4 – windows & doors
New high-performance windows, internal doors and external doors are installed.
Stage 5 – quality control
Final inspections are completed and site installation kits are prepared.
At this stage, the building performs like new, because, aside from the steel frame, it effectively is.
6. Finished & ready
Protected and prepared for delivery
Once complete, modules are:
- Structurally braced
- Weather-protected
- Wrapped and prepared for transport
They arrive on site ready for installation, delivering the appearance, quality and performance of a new modular building.
Why our approach is different
We do not overboard, cover up or reuse legacy components.
Leaving original materials in place can result in:
- Damp
- Mould
- Hidden structural issues
- Premature deterioration
By rebuilding from the steel frame up, we remove these risks entirely.
Although the original structure may not have been manufactured by Wernick, we still provide an extensive warranty, because we have full confidence in the quality of our refurbishment process.
Proven across multiple sectors
Our refurbishment methodology has been successfully applied across:
- Education
- Healthcare
- Commercial
- Leisure
- Construction
- Utilities
Each building benefits from the same rigorous, factory-controlled process.
