Warehouse at the Port of Southampton
17,875m2 of warehouse flooring
Install and finish high tolerance concrete warehouse flooring.
We were recently asked by main contractor Midas Construction and WFBA Consulting Civil and Structural Engineers to construct and install a pile supported ground floor slab at the new £23m 200,000 sq ft distribution centre for Import Services at the Port of Southampton (E208 Warehouse, Southampton Docks).
The warehouse floor slab needed to be incredibly high tolerance, in order to allow the warehouse racking to reach 13 metres high. This meant that it had to be installed in accordance with Concrete Society TR34 DM2. We put a plan in place and, just two weeks after the initial enquiry, we were on site to begin the mammoth task of prepping the floor.
The new warehouse site was designed to connect with Import Services’ existing quayside distribution centre, doubling their operational capacity. With an internal area of 17,875m2, the 250mm thick floor slab would require some 580 tonnes of bespoke mesh and loose bar reinforcement. All the required materials had to be carefully procured and resourced. In order to get the program back on schedule, four gangs of six fixers worked around the clock to get the reinforcement in place.
Three intense weeks of preparation later, the next phase of our works could get underway. With just over 4,500 cubic metres of C40 readymix concrete to pour, and a tight program to abide by, the Nationwide Concreting team would proceed with the huge challenge of completing 15 consecutive pours averaging 300 cubic metres per day. Working at the heart of one of the busiest ports in the country, the concrete was supplied by two CEMEX concrete plants and placed with Camfaud’s 42 metre boom pump.
Meticulous planning, consistency and efficiency were crucial to the success of this project. Our workshop team produced an inhouse rectifying machine which was subsequently used to assist in achieving the strict tolerances, and the finishing team worked through the night powerfloating the floor while scrutinizing every aspect. All our hard work ensured there was virtually no grinding to be done, and the client was left with a stunning concrete floor which will be host to several thousand linear metres of DM2 tolerance isles.
The whole team at Nationwide Concreting are exceptionally proud of our efforts here, with everyone doing their part to ensure each aspect of our works was a success. Most importantly, our client was thrilled with the work we did.