AXAIR Fans

Staffordshire | £580,000

Project Scope and Objectives

1. Site Preparation:

  • The project began with reduced-level excavation of an existing grassed area to prepare a stable foundation for the new extension.
  • The excavated area was designed to align with the level of the existing warehouse to ensure a seamless transition between the spaces.

2. Construction of the New Warehouse Extension:

  • The warehouse was extended using steel-frame portal construction, matching the design of the existing structure.
  • Wall cladding on the original warehouse was removed, allowing the two sections to form a unified, large internal space.

3. Structural Design Features:

Foundations and Flooring:

  • Concrete pad foundations were laid to provide robust structural support.
  • A power-floated concrete floor slab was installed to create a durable and smooth surface, capable of handling heavy machinery and operational loads.

Walls and Roof:

  • Masonry cavity walls and retaining walls were constructed for structural integrity and insulation.
  • Profiled steel cladding was applied to the walls and roof, maintaining consistency with the existing building and enhancing durability.

4. External Works:

  • The retention of grassed areas helped preserve the site’s landscaped appearance.
  • Paved margins were added to improve access, facilitate drainage, and provide a clean perimeter around the warehouse.

Challenges and Solutions

1. Limited Access:

The shared access road serving Units 1 & 2 posed logistical challenges during construction. The risk of disrupting operations for neighbouring units was significant.

Solution:

To mitigate these challenges, construction schedules were carefully coordinated to minimize interference. Deliveries and heavy equipment movements were planned during off-peak hours, ensuring smooth operations for all units in the vicinity.

2. Seamless Integration of Old and New Structures:

Creating a unified warehouse space without compromising the structural integrity of the existing building required precision engineering and planning.

Solution:

The removal of wall cladding and integration of steel portal frames were executed in phases, ensuring that the existing structure remained stable throughout. Detailed design coordination ensured that the new extension matched the dimensions, materials, and load-bearing requirements of the original warehouse.

3. Site Drainage and Landscaping:

Excavation and construction activities risked disrupting the site’s drainage and landscaping balance.

Solution:

The project incorporated paved margins to channel water effectively, reducing surface runoff risks. Grassed areas were retained and restored post-construction to maintain the site’s environmental appeal.