Polyseam Factory Extension.

While every site and client requirement present challenges, Polyseam presented several unique problems which needed to be resolved. 

The site was located between the clients existing production facility and a neighbouring engineering unit.  To the rear of the site was a canal with several house boats utilising the mooring points, and a well trafficked footpath.  The clients one way access road was located adjacent their existing factory, and it was imperative that the road remained accessible until an alternative road was completed for use by exiting delivery wagons.

The site sloped towards a busy road which was already affected by existing road works.  Sections of the site were affected by cellars while the remaining had been filled with debris to a depth of 5m.  The works relied on consultation with the British Waterways, Huddersfield Highways Department, the client’s Operations Director, neighbouring businesses, and the design team.  Among the innovations implemented to provide solutions on the site were:-

• Processing masonry and concrete from the cellars and other sources on site to produce suitable fill material to provide a designed piling mat and suitable sub-base material for the building and the external works.
• Developing a phased traffic management plan with the client to maintain traffic flow while the project was completed.  This included constructing a section of the building first and incorporating a new loop road so that the main traffic route could be maintained. 
• When the first phase of the building was completed, and the new exit route was formed, the second phase of the building was constructed which connected the existing factory with the 1st phase of the project.  This prolonged the programme, but it ensured that the client’s production was unimpeded.
• The piling mat was amended while the piling rig was on site to allow piles to be formed at two different levels.
• The drainage design was amended to suit the layout of the new road to allow the necessary amount of attenuation to be installed in 2No tanks.  This reduced the need for an excessively deep attenuation tank.
• The local engineering company was included in the scheme and supported financially by utilising their skills in providing specialist secondary steel work.
• New Section 278 works were programmed with the Highways Department to minimize disruption to the main access road.  These planned dates for the work were amended to allow for the completion of other partial road closures.
• New fencing was erected in a sympathetic manner to secure the clients property and to ensure the publics use of the waterways was not hindered temporarily or permanently.

The works were completed during the Covid pandemic by introducing strict health and safety measures and working with our supply chain to achieve a revised time frame which still achieved critical dates required for the client’s delivery of new machinery.