Careys Civil Engineering was principal contractor on this project, which encompassed the remediation and refurbishment of 67,000m2 of the existing hard standings at one of Sainsbury’s largest distribution centres. Works on-site included the breaking out of the old sub-base and stabilised material, which was subsequently crushed on-site and re-engineered into the capping layer before laying and compacting the sub-base layer. The replacement 230mm reinforced concrete slabs were then cast in sections across the site, with the new land drains installed following the removal of the existing surface water drainage. Once on-site, our team re-programmed the work to accelerate the original 136 week programme and successfully completed the contract 40 weeks ahead of schedule.

The concrete slab that was removed was crushed on site and recycled to be used as a 6F2 capping layer beneath the new slab, which was founded on a layer of cement bound material (CBM). We also constructed a new filter drainage system which helped dewater the site of existing ground water. 

Sainsbury’s distribution centre remained operational at all times and we maintained daily communication with the client to ensure there was no disruption to the 300 deliveries utilising the site. In addition to this, the project provided significant logistics challenges with materials/arisings areas located in front of “bays not in use”, being progressively moved throughout contract to correspond with construction phases.

All materials were transported from storage areas to the work areas by dumper/pick up with the exception of reinforcement mesh which was slung from excavators by chain and transported to the work area with banksmen escorts. A Heras fence opened as required for vehicle access, but remained closed at all other times.

The project was completed to a fast-tracked 84 week programme and delivered in just 52 weeks, over 30 weeks early, all whilst keeping the busy distribution centre fully operational. Whilst on site, the team won a number of client site safety awards, as well as a Smartwaste Award in the category of best large refurbishment project. The team also got involved in a number of charity events, including a sponsored truck pull.

Sainsbury's Supermarkets Ltd.
Sherburn, North Yorkshire
Principal Contractor
Careys Civil Engineering
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