Project
Desford leicestershire
project management, refurbishment, mechanical, furniture
72k
build
Roshal completed the refurbishment of the Control Room at Caterpillar, transforming an ageing operational area into a modern, functional and efficient working environment.
Located at the heart of the factory, the Control Room provides a central point for monitoring and controlling key factory operations, including machinery, cranes and engine-related systems. Because the room plays such an important role in the day-to-day running of the facility, Caterpillar needed the refurbishment to progress without compromising operational continuity.
For this reason, Roshal developed a carefully coordinated approach that allowed the refurbishment to progress while maintaining access to critical control systems.
The live factory environment presented a significant challenge from the outset. The control panels and monitoring systems remained operational throughout the project, allowing engineers to maintain access to essential factory controls.
To accommodate the refurbishment, the engineering team’s workstation moved temporarily to another location. However, the Control Room itself continued to support essential operations.
As a result, Roshal carefully planned each stage of the works around the operational requirements of the engineering team. This approach allowed the refurbishment to progress safely while minimising disruption to the wider factory.
At the same time, Roshal maintained close coordination with the wider project team to manage access, sequencing and health and safety requirements.
Roshal began the transformation by completely stripping out the existing Control Room. The team removed the existing fixtures, fittings, furniture, redundant equipment, floor coverings, ceiling system and associated materials.
The team then dismantled and removed the central dividing metal wall. Before starting this work, Roshal isolated and protected the relevant services to prevent damage to critical systems.
Once the strip-out was complete, the team prepared the room for its new layout and finishes. As part of this preparation, Roshal infilled three existing windows internally using studwork and plasterboard. The team then finished the external faces with painted plywood to complement the surrounding structure.
This preparation created a clean and practical base for the next phase of the refurbishment.
With the strip-out complete, Roshal moved into the main refurbishment phase. The team introduced a range of new finishes and fixtures to create a contemporary environment that could withstand the demands of a busy operational space.
The refurbishment included:
Together, these improvements gave the Control Room a fresh and cohesive appearance while providing durable finishes for everyday operational use.
The refurbishment also needed to connect visually with the wider workplace improvements taking place across the Caterpillar facility.
To achieve this, Roshal installed acoustic slatted timber wall panelling to the monitor wall. The feature wall adds visual interest while also helping to improve acoustic performance within the busy Control Room.
Furthermore, Roshal incorporated Caterpillar’s established brand colours into the design. The team also coordinated the feature wall with the workstation layouts and slatted wall treatments already introduced elsewhere within the facility.
Consequently, the Control Room now sits comfortably within the wider workplace design rather than appearing as a standalone refurbishment.
Alongside the main refurbishment, Roshal introduced a new compact kitchen to improve staff welfare and day-to-day functionality.
The team installed:
By incorporating the kitchen within the refurbished space, Roshal provided the Control Room team with a practical welfare facility without compromising the available working area.
Roshal also installed a new sliding access hatch within an existing window opening.
The hatch provides a secure point for communication and document exchange between departments. In addition, the design incorporates lockable functionality and shelving on both sides, giving staff a convenient location for paperwork handling.
This small but practical addition improves communication between teams while maintaining a secure and organised working environment.
The result was a complete modernisation of the control room without compromising operational continuity.
Once the refurbishment works had progressed, Roshal supplied and installed a complete furniture package tailored to the operational requirements of the Control Room.
Rather than using a standard furniture arrangement, Roshal selected and positioned each element to support the way the team uses the space.
Roshal installed six operator workstations in a back-to-back configuration using Mesa Plus desks with elm-finished tops and black leg frames.
The furniture complements Caterpillar’s existing workplace standards and creates a consistent appearance across the site.
Each workstation includes:
This arrangement gives each operator a dedicated workspace while keeping the room organised and efficient.
To support the operational requirements of the room, Roshal installed three lockable desk-height storage cupboards.
Each cupboard includes adjustable shelving, allowing the team to adapt the storage space for operational equipment, paperwork and documentation.
As a result, the Control Room benefits from additional storage without taking up unnecessary floor space.
Roshal also created a dedicated bench-style worktop in front of the monitor wall.
This additional surface provides a flexible area for monitoring activities, paperwork and collaborative working. Two Vision operator chairs complete the arrangement, allowing the space to serve a range of operational requirements.
The refurbishment extended beyond the main Control Room to include an improved harness storage and changing area.
Roshal installed:
These improvements provide staff with a more organised, secure and practical area for changing and storing personal equipment.
Throughout the project, Roshal coordinated the building, refurbishment and furniture elements to maintain a consistent programme and minimise disruption to Caterpillar’s operations.
Roshal’s works included:
Electrical works formed part of the wider project and were completed by others. Nevertheless, Roshal coordinated its activities with the wider project delivery team to ensure each element progressed safely and efficiently.
This coordinated approach proved particularly important within the live factory environment, where the team needed to balance construction activities with the continued operation of critical control systems.
The completed refurbishment has transformed the Control Room into a modern and professional operational environment.
The new finishes, acoustic treatments, welfare facilities, storage solutions and purpose-designed furniture work together to create a space that is both practical and visually consistent with Caterpillar’s wider workplace environment.
More importantly, Roshal delivered this transformation while working around live operational systems and maintaining access to essential controls throughout the project.
Ultimately, the refurbishment provides Caterpillar’s Control Room team with a more comfortable, organised and efficient working environment. At the same time, the project demonstrates Roshal’s ability to deliver complex refurbishment works within a live and operational industrial facility.
By combining careful planning, detailed coordination and a complete refurbishment solution, Roshal successfully modernised a critical operational space while supporting Caterpillar’s continued investment in its workplace.
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