Overview
Client: CBRE/CarnaudMetalbox
Duration: 28 weeks
Value: £4m
As a leading producer of machines for food and aerosol manufacturers, CarnaudMetalbox has seen growing demand for its products. In order to significantly increase its capacity and provide customers with a full solution, leasing of the 150,000 sq. ft. warehouse has significantly increased its footprint in the UK to compliment it’s existing global estate. The new unit is to be used for the assembly, testing and despatch of the company’s product portfolio and will also enable it to expand its in-house manufacturing capabilities into one site.
The Brief
As the leading contractor, Sigma was commissioned to transform the disused warehouse, together with annexe office space, into a modern, future-proofed facility. A project of this breadth and scale, that involved everything from the specification and installation of a new roof, to a complete bespoke M&E package, the facility required significant investment in infrastructure, welfare and capital equipment, before the fully functioning assembly, testing and dispatch facility was complete.
The Challenge
The extensive transformation of this very large facility required a fully coordinated approach between the Sigma teams, ensuring that the multi-faceted work taking place ran smoothly, efficiently and to schedule. As the lead contractor, Sigma’s task required expertise in demolition, construction and installation, covering aspects such as:
- Full refurbishment of the warehouse, welfare areas and office spaces
- Demolition of the on-site garage
- Stripping out and clearing of the adjoining office building to create a ‘white box’ space
- Site-wide installation of sustainable, LED external lighting, with sensors
- Demolition of the gatehouse and installation of a modular replacement, including all M&E
- Installation of entrance barriers, including necessary ductwork
- Replacement of gates and decoration of existing gates
- Completion of all groundworks, including ductwork and trenching for lighting and widening roads
- Landscaping, including cutting back trees, digging up borders and grass cutting
- Liaison with GNER to ensure no impact to the electrified lines next to the site
- Stripping out and replacement of all old M&E - including air conditioning
- Bringing fibre cables onto the site and into the new offices
- Installation of all data cabling
- Main panel board switch over and installation of section boards
- Installation of 60 tonnes of power cables across the site
- Decoration of all external panels on the building to match CarnaudMetalbox branding
- Completion of full CCTV survey of the existing drainage, clearing any issues
- Bird boxes placed around the site
Works specific to the warehouse:
- Safe removal of asbestos roof and installation of new composite panel roof. TOR coating of some of the existing roof still in satisfactory condition to increase lifespan
- Grinding and cleaning the floor to remove old paint and floor lining
- Installation of cabling to ensure machines could be correctly located
- Installation of space heating heaters throughout
- Data cabinets fitted to the client’s requirements
- Remedial brickwork
- Replacement of roller shutter doors and steel fire doors
Works specific to the annexe:
- Repartitioning of certain areas and decoration
- Installation of new doors, floors and ceilings throughout
- New welfare area fitted out with new kitchens, canteen and sinks
- Installation of new datacentre
A proactive, end-to-end solutions provider
Sigma worked proactively with both the client, CBRE, and the end customer, CarnaudMetalbox, liaising with them throughout the project, ensuring all parties were kept up-to-date. When unforeseen circumstances arose, the Sigma team recommended appropriate solutions. These included:
Roof alterations
Sigma recommended composite panels be fitted to the warehouse roof to speed up the installation, as they are quicker to install than the twin-skin roof originally specified. Sigma also collaborated with structural engineers to ensure the roof would be adequately supported.
Office building retention
Though the original plan was to demolish a detached office building at the front of the site, Sigma believed this was not the most efficient and cost-effective option and recommended that the office should be expanded and refurbished. This was agreed by CBRE and CarnaudMetalbox. This project, at the time of writing, is currently at costing stage.
Asbestos removal
Sigma raised concerns that asbestos materials remained in certain parts of the building, specifically in some of the warehouse wall cavities. Further investigation showed this to be the case and its safe removal was carried out in compliance with the Control of Asbestos Regulations 2012. This ensured that the facility was handed over to the client in a safe condition.
Supply issues
As a number of supply issues within the industry and out of Sigma’s control, held back the completion of the scheme by several weeks, Sigma re-arranged its programme of works to ensure the client could move into the building at the agreed time and commence its on-site activities without delay.
Sustainability
Sigma, CBRE and CarnaudMetalbox are all committed to improving sustainability and this was an important aspect of the project.
The work involved installing modern, energy-efficient LED lighting and heating systems, the safe removal and disposal of hazardous asbestos and, where feasible, areas like the office space were refurbished rather than replaced. Sigma also helped to reduce the project’s environmental impact by using renewable and recyclable resources wherever possible, implementing sustainable working practices and carrying out effective waste management and recycling during the project.
The Outcome
The new facility has been occupied by CarnaudMetalbox since September. The additional space expands its production capacity, enabling it to keep up with increased demand, while the new assembly, testing and despatch facilities at the site will help it speed up production, improve quality control and dispatch products quicker and more effectively.
Sigma is proud of the extensive refurbishment work it has completed during the project and of our success in working closely with clients and subcontractors. Both CBRE and CarnaudMetalbox are highly satisfied with the finished building, the quality and effectiveness of our work and our transparent and collaborative approach.
“We are extremely pleased with the level of service, workmanship and support everyone at Sigma has demonstrated over the course of the project. The team has not only shown professionalism across all disciplines, it has also been pro-active, amenable and flexible in unexpected circumstances, which has ensured we now have a top class facility to work in”
