Client: Wavin Ltd.
Form of Contract: JCT D & B 2011
Value: circa £5,000,000
Duration: 19 Months
Date: April 2015 – November 2016
Project Manager: ICR Project Management Ltd, Bolton
Wavin Factory, Chippenham
KEY FACTS
- Remodelling of existing car park to increase size by 1,000m2 including access for pedestrians
- Recycled existing concrete stock yard into power floated floor slabs for factory extension
- Construction of a 200 space car park on green field site
- Construction of a new 11,000m sq stock yard on green field site
- Construction of a 0.5km adoptable link road to service new configuration
Project scope
Wavin is a European leader in the production of plastic plumbing, rainwater and drainage systems. Across 25 European Countries, Wavin manage 40 manufacturing sites with a large manufacturing facility in Chippenham, Wiltshire.Due to increased demand and business growth, the Chippenham factory required an extension with an additional product storage area and increased car parking facility. The project involved five key elements that were phased to ensure minimal disruption to ongoing operations at Wavin.
Project details
Car Park Remodelling - The first project involved the remodelling of an existing 1,400m sq staff car park, together with the conversion of a 1,500m sq lawn area to make a total of 122 car parking spaces. The areas were excavated and levelled, surface water drainage and an attenuation tank were installed and levels were built up to create a suitable foundation. Additional works included the paving of pedestrian walkways, new cycle shelters and a staff rest area.Factory Extension - The factory was expanded to include new ancillary buildings requiring four bay extensions measuring 8,000m sq. We excavated and re-crushed the existing concrete yard to produce 4,800 tonnes of Type 1 to use as a fill material on site. We then constructed power floated floor slabs to SR2 standard and installed three new drainage attenuation tanks. This was followed by the construction of a new substation, transformer house and concrete bases for three new bulk silos.
Additional Car Park - Built from a greenfield site opposite the factory, we built a 200 space car park complete with extensive drainage using a modern Sustainable Urban Drainage System, with seven Aquacell storm water attenuation tanks to control the flow of surface water. We collaborated early with Wavin to design the drainage within the car park, using Wavin products to save the client additional costs. The area was completed with a combination of block paving and an asphalt surface course.
New Storage Yard - To house additional products, we constructed a 11,000m sq surfaced storage area. Working under a 33KV high voltage cable meant that all operations were carefully planned to minimise risk to operatives and drivers. Specialist non tipping trailers were used in the delivery of materials to avoid contact with the cable.
New Link Road - The final project to build a 0.5km highway adoptable link road required 3,900m cu of material to be excavated, and the import of 2,000 tonnes of in-house recycled 6F5 and 1,000 tonnes of Type 1 to build the foundation. A drainage run, Aquacell tank and gullies were installed in addition to 862m of kerbing prior to being surfaced. A culvert was also built to highway standards to link in with a nearby future proposed ring road.
