sbh.uk masterminds complete warehouse fit out for A.S. Watson Distribution

Warehouse and distribution property specialist sbh.uk has recently completed the project management of an extensive multi-million pound fit-out for leading health and beauty company A. S. Watson's new 45,000m2 (500,000ft2), 15m (49ft) eaves height southern distribution centre in Dunstable, Bedfordshire. A. S. Watson took over the new warehouse shell from developer ProLogis ready for fitting out in September 2006, and the work was finished on time for occupancy in July 2007. The project included 1,800m2 (20,000ft2) of offices, with 69 doors, dock levellers and scissor lifts for access to the warehouse, on a 45-acre site.

Located close to the M1 and other transport routes, the centre serves Superdrug and Saver stores across the country. A. S. Watson Group (ASW) Family is the world's largest health and beauty retailer with a network of 7,800 retail stores globally with stores in over 1,800 cities and with more than 98,000 employees.

The extensive fit-out specification comprised high bay pallet racking served by reach trucks in the main warehouse, with special provision including in-rack fire control sprinklers for aerosols and other flammable products in a caged, fire-protected zone. Other works included a staff kitchen, canteen, locker rooms, reception areas and sanitary facilities; external works including a vehicle wash and fuel island; and full electrical and mechanical works including a battery charging bay for the fleet of reach and fork trucks.

As project managers, sbh.uk's team - based both on site and in their Cheshunt head office - planned and co-ordinated the work of some 16 different subcontractors, providing the overall direction and organisation of the entire fit-out project. Their role also meant taking full responsibility for all enabling works such as temporary accommodation and services, site security, health and safety, managing material deliveries and stock control. With quality a priority, sbh.uk managed and monitored the standard of construction during the defects liability period from initial practical completion back in September 2006. By Autumn 2007 remedial work was virtually complete with only a few minor tasks outstanding.

sbh.uk's Steve Lamb described some of the challenges the project presented. "A.S. Watson and Superdrug's specification was achievable within a tight budget but we needed to manage each stage and operation very carefully to ensure there was no overrun. Fortunately we were working with a number of contractors such as PWP Building Services that we knew from experience we could trust, and the task of co-ordinating so many different trades - many of whom were on site at the same time - was one we have faced on numerous occasions on other warehousing projects of this scale."

The standard shell included largely basic services and the earliest task that fell to PWP Building Services was to upgrade and extend the electrical fit out. From the two megawatt feed and main switch supplied, PWP extended the main panel, added a number of outgoing ways, automatic changeover equipment and a one-megawatt standby generator.

The enhanced Main Panel was used to feed power to 700m of lighting busbar, 2,600 high frequency fluorescent lights, complete with automatic aisle lighting with microwave motion detection sensors and 328 Metal Halide highbay lights. With environmental issues now to the forefront, the Metal Halide lights were fitted with automatic detectors so they operate only when there is insufficient natural daylight, saving energy.

Other equipment and systems installed included 200 PA speakers, supplies for battery charging, sprinkler pump house supply and various installations specified by the client including vehicle wash, fuel island pumps and salvage area services.

With so many high value products in store, many containing volatile chemicals, the high density sprinkler system was designed to cover the entire warehouse roof area, giving the client maximum storage flexibility. The automated system designed and installed by Alpine Fire Engineers provides for 27 in-rack sprinklers operating simultaneously with the roof system above. A total of 22,000 sprinkler heads were installed in the racks, supplied by 41km (26 miles) of steel pipe work. Three half-duty diesel fire pumps with a combined duty of more than 16,000 litres/minute are supplied from 2 water storage tanks with a capacity of some 1.37m litres (2.5m pints) of water. Alpine's design was to BSEN 12845, with minor modifications as required by A.S.Watson's insurers.

The major exterior works included elements now generally required for major distribution centres but which speculative shell schemes rarely include, namely vehicle wash facilities and on-site refuelling. Because of the nature of the market in which it operates it was particularly important that the company had the means to ensure that its vehicles could be kept clean at all times.

The fully automatic, three-brush moving gantry vehicle wash unit supplied and installed by Brendeck Ltd is capable of washing commercial vehicles up to 5.0m high. The design incorporates an environmentally responsible and cost-saving full water recycling system and an integrated pressure wash unit, with the complete facility enclosed within a portalised screened wash bay.

For on-site refueling, the company opted for a 52,000-litre dual compartment, totally enclosed bunded fuel storage tank to store and dispense diesel and engine oil on site. Fueltek, a Blackburn-based specialist designer and manufacturer, supplied the entire fuelling system including state of the art electronic dispensers for diesel and gas oil, linked into a fuel management system to give important management information on fuel usage.

The company also supplied air and water facilities to enable all the functions normally undertaken at the fuelling point to take place at the company's own on-site forecourt facility.

The storage, handling and order picking systems have been in operation for a few months and have bedded down well. Pallets are stored up to nine high on 12m Link 51 high pallet racking in 38 aisles accommodating up to 53,000 pallets, although only some 16,000 are currently in store. The 3.1m aisles are accessed by a fleet of reach trucks. Operatives receive picking instructions through a Vocalect voice-directed picking system linked to Superdrug's infor-based WMS.

Aerosol based products are stored in a high security caged zone measuring 2,950m2 (32,000ft2), fully enclosed from floor to ceiling. Goods are stored and picked using a mix of pallet racking, Carton Live Storage - also supplied by Link 51 - and a carousel unit for retail samplers.

The centre currently ships out around 30 vehicle loads each day to stores in the South East and to its Northern RDC, but this volume is expected to more than double as the facility builds up to full capacity during 2008.

sbh.uk
Laurie Sice
Tel: 0870 60 60 123