Project Description

FP McCann Precast Concrete Vehicle Docking & Insulated Prowall System Installed At New Arco Distribution Hub

Status: Completed

Location: Hull, Humberside

Division: Dock Leveller Pits

Main Contractor: Clugston

Market Sector: Commercial


FP McCann’s specialist precast concrete installation team has undertaken the build of a multi-vehicle docking and insulated prowall system on a brand new 20,439m² distribution centre in Hull, Humberside. Workwear and safety equipment supplier Arco, is doubling its warehouse and logistics capabilities by linking the brand new facility to their existing building. When operational later this year, it will have a 19m storage height capacity, capable of holding around 40,000 pallets.

ARCO appointed Scunthorpe based construction group Clugston as the main contractor earlier last year, and Clugston, in turn, employed the services of FP McCann’s skilled precast concrete Dock and Prowall fixing team to install the FP McCann package of in-house designed precast products.

The new warehouse once complete will provide HGV loading via 15 number dock levellers 3.0m long x 2.0m wide x 1.25m high and 2 number Euro dock levellers 3.5m long x 2.0m wide x 1.25m high. Each Dock Leveller is fully supported by a precast concrete Dock Leveller Pit. The precast pits are formed from a combination of front walls, rear walls, side walls and biscuit slabs. The biscuit slab spans from the front wall to the rear retaining wall to form an opening for the Dock Leveller to be suspended from. These panels form a continuous precast structure complete with 3.0m tailgate slots for multiple pit installations without creating the need to backfill between the pits. Above the Dock Leveller Pits are 87 linear metres of insulated Prowall panels with a U-Value of 0.27W/m²K.

The Prowall system is designed to cater for standard dock shelters to a height of 3.6m above the 15 standard pits, and 2 number dock shelters 4.6m high above the Euro dock pits. Each panel is supplied and installed complete with one 3.0m high x 3.0m wide door opening for vehicle access.

As part of the perimeter wall to the building, a further 68 solid insulated spanning Prowall panels totalling 496 liner metres have been installed. The spanning Prowall panels were utilised as the panel design incorporated an integral ground beam which reduced the need for continuous strip footing to each steel bay, saving time and money on-site. The building perimeter panels include 8 personnel door openings and 1 double door fire exit along with window requirements to the office. All of the panels have a smooth acid-etched finish and additionally, the outer skin has been pigmented a colour-stable dark grey to match the architect’s design specification.

To form the required service yard gradient, two runs totalling 44 linear metres of drilled and dowelled precast yard retaining walls were installed. Transported from the company’s Byley and Littleport manufacturing plants in Cheshire and Cambridgeshire, Dock Leveller Pits together with the Prowall panels were delivered to site on a ‘just in time’ schedule. Once on-site, all precast concrete dock units and insulated Prowalls were lifted from the vehicles and placed directly into position in one single and safe operation. The fixers then secured the panels to the building’s steel frame.

Commenting on the insulated Prowall and Dock Leveller Pit construction, John Everitt, project manager for Clugston says, “This precast concrete system lends itself in particular to a safe, speedy and very efficient build. FP McCann’s fixing team are fully versed in this precast system and their working process complements the Clugston site construction methods and practices. The utilisation of the FP McCann Precast Dock and Prowalls dramatically reduces the installation time when compared to a more traditional build.”