CASE STUDY
Whilst factories were at risk, Stark created a stress-free experience whilst upgrading critical infrastructure.
Background
Ibstock approached Stark due to concerns about an aged gas plant at their Leicester Road site (their Head Office and flagship location with three operational factories) that was at risk of sudden failure, with lengthy lead times for replacement parts.
The existing gas metering system consisted of outdated equipment that required urgent upgrades, capacity reductions, and measures for decarbonisation.
Many of the meters were failing to provide accurate consumption readings, resulting in billing discrepancies and increased operational costs.
With three factories at risk, Stark created a solution to ensure the gas meter exchange was a seamless experience.
The project
Stark was nominated to become the Meter Equipment Manager (MEM) and Data Collector (DC) to restore the metering portfolio to full confidence.
Led by Stark’s Ethan Clinkscales, the team systematically exchanged Ibstock’s gas metering portfolio, working around their shutdown windows to minimise disruption.
Ethan’s meticulous construction phase plan and excellent leadership were instrumental in the project’s success. His collaborative approach and clear communication made the entire process smooth for all stakeholders, while his dedication to Health and Safety ensured robust and practical safety measures throughout the project.
“Ethan’s construction phase plan was of exceptional quality and accuracy. His meticulous attention to detail ensured that every aspect of the project was thoroughly planned and executed flawlessly. His depth of knowledge in this field was evident, and it greatly contributed to the success of the project.”
Tom Blagden, Project Manager, Ibstock
Challenges
The project faced three key challenges in the exchange process.
Firstly, the meter housing presented limited access, which led us to design a modular installation that could fit through tight doorways.
Secondly, the existing installations featured complex pipe connections. To address this issue, we engaged an on-site fabricator who produced custom spools, thus avoiding potential delays.
Lastly, legacy downstream systems hindered the safe removal of old meter installations.
To facilitate this, our in-house fabricator implemented hot tapping and drilled connection points for effective purging, adhering to bespoke Risk Assessment Method Statements (RAMS) approved by our in-house engineer.
Outcome
The project resulted in accurate billing and improved investment insights for Ibstock, significantly reducing downtime risks. The client appreciated the team’s collaborative and communicative approach, with special recognition for Ethan’s leadership and technical expertise.
Stark continues to provide technical support from IGEM chartered engineers and has invested over £571,000 in upgrading gas infrastructure for long-term supply continuity at Ibstock sites
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To discuss how we can assist you with your gas metering, drop us a message by completing our contact form.
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