Project Stats
Project Brief
This project formed part of the 125th anniversary celebrations of The Hawthorns Stadium. GI Sykes was appointed to carry out a full external refurbishment and protective coating programme to all four stands, associated steel structures, and bespoke floodlight towers. The works were complex due to the age of the stadium, the varied nature of the substrates, and the logistical constraints of working around major highways, a school, and active club operations.
What we did
The brief required the preparation and recoating of extensive areas of plastisol cladding, structural steelwork, window frames, louvres, doors, railings, and significant bespoke floodlight structures. Given the stadium’s mixed construction and differing exposure conditions, each stand and corner required a bespoke approach, tailored access solutions, and careful planning to ensure both safety and quality.
Due to uncertainty surrounding the condition of the floodlight towers, roof steels, and the need for permits for pavement and lane closures, GI Sykes initially advised a programme of 30 weeks. Through meticulous planning, high productivity, and continuous coordination with the club and local authority, the works were completed in half the expected duration.
Access & Logistics
The Hawthorns is bordered by two busy roads, one being a primary route from Birmingham City Centre to M5 Junction 1, and the other situated adjacent to a school. Because of this, significant traffic management, lane closures, and pavement closures were required. The local authority granted limited working windows, primarily during school half‑term periods, which demanded a highly flexible and responsive programme.
Due to the varied geometry of each stand, access methods included:
- MEWPs
- Rope access teams for high-level steel trusses and floodlight structures
- Scaffolding
Every stand and individual corner were treated as a self‑contained project due to their differing conditions, heights, and access restrictions.
Surface Preparation & Environmental Controls
Many areas of cladding exhibited severe blistering and degraded overcoatings. Preparation included:
- High‑pressure jet washing (up to 4000 psi)
- Mechanical removal of loose and flaking coatings back to a firm edge
- Specialist cleaning and degreasing of metal substrates
- Careful containment procedures to prevent debris from entering the pitch
Particular consideration was required during pitch replacement works in pre‑season. Road sweepers were utilised to clean external elevations and prevent paint fragments or debris from entering public areas.
Coating System
All works were undertaken strictly in accordance with PPG’s project specification and product data requirements, including:
- Johnstone’s Steel & Cladding Semi‑Gloss Topcoat
- Johnstone’s Performance Coatings Smooth Metal Paint
- Specialist primers and mordant solutions for galvanised and previously coated metal
Each element was applied to achieve the required film thicknesses, with additional stripe coats to welds, edges, fixings, and sensitive areas to ensure long‑term durability.
Project Results
Despite the bespoke nature of the project, the environmental challenges, and extensive access demands, GI Sykes delivered the full refurbishment in just 15 weeks, significantly ahead of programme. This achievement is a testament to the diligence and professionalism of the on‑site team, access specialists, and project management.
The completed works revitalised the stadium’s external appearance, ensured long‑term protection of its structural elements, and aligned with the club’s 125th anniversary celebrations. This high‑profile refurbishment has enhanced the visual impact of the stadium while extending the lifespan of its external fabric and steelwork.
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