Our Project

Pipe Storage Facility

Client: GPS PE Pipes Contract Value: £6,000,000 Contract Duration: 40 weeks

The Client

For many years GPS PE Pipes have utilised a nearby
former airfield for storing their product prior to sale
to its customers. Due to a change in the local plan,
GPS required a site of their own, near to their factory
in Huntingdon.

GPS, together with their consultants MTC Engineering,
developed a scheme to provide a secure, lit, free
draining new 75,000m2 new facility to provide for
their future needs. Fox were awarded the Design and
Build contract to finalise the pavement design and
construct the new site. Following this, we were also
awarded the Section 278 scheme which provided an
upgraded site entrance to the existing industrial park.

The Project

For many years GPS PE Pipes have utilised a nearby
former airfield for storing their product prior to sale
to its customers. Due to a change in the local plan,
GPS required a site of their own, near to their factory
in Huntingdon.

GPS, together with their consultants MTC Engineering,
developed a scheme to provide a secure, lit, free
draining new 75,000m2 new facility to provide for
their future needs. Fox were awarded the Design and
Build contract to finalise the pavement design and
construct the new site. Following this, we were also
awarded the Section 278 scheme which provided an
upgraded site entrance to the existing industrial park.

Project Completion

On award, we immediately progressed a review of the existing design. This led to a number of value engineering suggestions which the client adopted and used to enhance other parts of the scheme. We also prepared our detailed design of the pavement scheme, reviewing options and obtaining client approval. We adopted a ground stabilisation solution with Roller Compacted Concrete (RCC) surfacing. At commencement we initially had to undertake vegetation clearance and ecology work to allow construction of the outfall through an area identified as possible great crested newt habitat. We then commenced the construction of sitewide drainage which required more than 60 catchpits and 1.5km of twinwall drainage to depths of up to 4m.

The drainage scheme also required us to construct an attenuation basin, hydrobrake on the outfall and petrol interceptor. Along the southern boundary, we also constructed 400m of filter drain. Following topsoil strip, a two stage ground stabilisation programme was then commenced. This was out suggestion since the ground investigation identified low CBR which led to an uneconomic pavement design with significant muck away and import of Type 1. The stabilisation required a first pass of lime modification and deep rolling dynamic compaction to dry out the subgrade and compact deeper made ground. Following this, the ground was mixed insitu with cement and water to stabilise the ground and act as a sub base replacement onto which the pavement would be laid directly.

As ground stabilisation works progressed, we mobilised our specialist paving subcontractor to site. Due to the quantities of material the RCC was batched on site. We prepared a pad and designated haul route with enhanced ground stabilisation to allow for the batch plant and associated equipment. The RCC paving was 72,000m2 at 250mm thick and undertaken using two gangs, working in difficult weather conditions to complete the site pavement. A surface treatment was also applied along with a power float finish. Following completion of the RCC, we raised the ironwork and poured insitu concrete around the catchpits. The lighting scheme for the site included 34 15m high columns with between 2 and 3 LED units on each. We planted columns in twinwall sleeves to allow future maintenance. The lighting scheme also required construction of a new feeder pillar for the site and associated ducting and cabling around the site perimeter. We also provided ducting for CCTV and BT and protection barriers to the columns. Other site services included installing new site office cabins, a package foul water treatment system and power to both.

Security for the site required us to construct a new fence to the perimeter in addition to new powered gates. The perimeter fence comprised 700m of 2.1m high palisade and 800m of 2.1m high chainlink with barbed wire. Two powered gates and an automatic
barrier were also installed. This included a 12m long powered cantilever sliding gate with remote control. The site also required a landscaping scheme, shrub planting to the perimeter and hydroseeding of verge and pond areas.

The Section 278 works were undertaken concurrently with the main site build. The value of this work was approximately £200,000 and included construction of a new right turn into the site, new traffic islands, modifications to the drainage and changes to the lighting on site. Following this, the entire area was planed out, resurfaced and white lined.

Achievements

Our work on this site provided a high quality, high specification build. To keep to programme, we structured the build to overlap many different aspects together such as stabilisation/RCC/lighting/S278 which required our team to maintain meticulous plans to ensure that the critical path was honoured.

The S278 work was particularly challenging, as the industrial estate is very busy with a number of logistics companies operating on site. We had to maintain uninterrupted access to the site.