Delivered on a challenging greenfield site adjacent to a historic airfield and intersected by a significant gas pipeline, this 800,000 sq ft logistics warehouse was designed around the operational requirements of T J Morris’ Mechanical Handling Equipment (MHE).
The building includes high (34m) and low (22m) bay warehouse areas, offices, freezers, MHE pits, and extensive service yards. The site posed significant geotechnical challenges, including UXO risk and complex ground conditions, addressed through a 200,000m³ cut and fill operation in mudstones, with lime and cement stabilisation to optimise balance and create temporary working platforms.
A critical success factor was the floor slab design, tailored to meet the MHE system's strict settlement and performance criteria. Over 14,000 precast driven piles with “mushroom” heads were installed with tight settlement limits, supporting suspended, fibre-reinforced slabs with a differential settlement tolerance of just 1:2500. An innovative construction sequence allowed early erection of the low bay frame, which provided temporary stability for the high bay steelwork, ensuring smooth progress despite height and column spacing complexities.
Early access milestones were required to support the phased installation of MHE, with tight coordination between the construction and client fit-out teams. Full MEP fit-out, including fire protection and post-completion services, was delivered in parallel. The warehouse now functions as a high-performance logistics hub, precisely aligned with the end-user's operational needs.
Sustainability was a key priority, with the installation of rooftop PV panels, EV charging points, and a large attenuation pond to manage surface water runoff. The project is targeting BREEAM “Very Good” and incorporates ecological landscaping to support biodiversity. Community engagement and use of local suppliers added social value, underlining the project’s broader positive impact beyond its technical achievement.