Story were engaged by long-term client, Pirelli UK, in a single source tender process for the design and build of a new extension at their factory in Carlisle, which would house elements of their curing process.
Story were engaged by long-term client, Pirelli UK, in a single source tender process for the design and build of a new extension at their factory in Carlisle, which would house elements of their curing process.
From early design the client had expressed the necessity, to have a completed floor within 18 weeks following the installation of the gallery pits (some 65m long stepped to fall from 1.0m to 2.0m) including service tunnel (3.5m below ground to link with existing tunnel).
This posed a significant challenge as it meant the structure had to be complete, with roof, to allow the construction of the pits. This meant that adherence to the project programme was critical, with Story and all the associated sub-contractors working collaboratively throughout the works to ensure the successful completion of the project with 1 week to spare.
20,000t
material utilised in cut and fill works
800m3
concrete poured to floors, pits and foundations
The project involved the following main elements of design and construction:
• Raising of ground levels as required to infill lower level existing topography and maintain existing factory floor level for the footprint of the proposed extension, incorporating steps in level for Curing gallery and closed duct etc.
• Construction of extension superstructure, including linking to existing structure and accommodating any future extensions
• Diversion of existing surface water drains to accommodate new gallery pits
• Excavation of gallery pits and service tunnel
• Construction of new gallery pits and floors
• Cladding works to roof and walls
• Design to accommodate services and machinery installation by Pirelli
• Internal fire resistant rapid roll doors and internal 2 hour fire resistant wall compartmentation upgrade
• Surface and roof drainage, including fire road land drains
• External ground levels raised for provision of perimeter fire road with stable embankment beyond
• Realignment of external site security fencing.
Due to machine delivery dates dictating the required programme completion date, this project was delivered within an challenging timeframe, which even Pirelli were sceptical could be achieved. 12 weeks into the project Pirelli made the decision to extend the building by an extra 2 bays (another 600m2). This was designed and constructed in less than 12 weeks to allow possession for the client to install further machinery procured by Pirelli Global.
Our long-standing relationship with the client enabled early engagement in a collaborative design process, resulting in time savings on the project. Further time savings were also generated through phased handovers, allowing Pirelli to proceed ahead of programme. Our commitment to being a stress-free contractor was also evident, with no disruption or downtime caused to Pirelli’s manufacturing process, despite works taking place in close proximity to the manufacturing line.
Network Rail
The project involved regrading approximately 280 metres of the embankment to enhance structural stability and improve rail safety.
RWE Renewables
Works were carried out to demolish an existing storage building, and replace it with a larger, modern structure.
Network Rail
VolkerRail/Story joint venture were tasked with the £80m project as part of a £137m investment that saw the undertaking of extensive enhancement works to remove several bottlenecks along the route to improve reliability, increase passenger services and aid in freight movements.