Warehouse Construction Staffordshire

Our warehouses are constructed to match the way your business operates, not merely to have a roof. Staffordshire is situated on the M6, the main north-south road used for freight transport through the central part of the country, and has a well-established manufacturing background. Warehouse Construction Contractors handles the entire process, from the distribution sites located on the motorway through to the factory units and storage buildings all over the county. If it's a new build, an extension or a refurbishment, our single team will handle the project from the very first site visit right through to handover.

Warehouse Construction Staffordshire

Warehouse Development in Staffordshire

Staffordshire is a very well-placed logistics region in England due to its location along the M6 Motorway. The M6 Motorway acts as the primary trunk road connecting the South, Midlands, and North-West of England. In addition, the M6 Toll provides an alternative route around traffic congestion associated with the M6 Motorway in the vicinity of Birmingham. This makes Staffordshire a logical base for distribution operations that service the majority of the United Kingdom.

In Stoke-on-Trent (the northernmost urban area), there exists a long history of ceramic manufacture. The city continues to be one of Britain’s major manufacturing bases. Stafford, also known as the county capital of Staffordshire, is located approximately halfway along the M6 Motorway. The city has been designated as a 'Motorway Town' by the UK Government. To the east of Stafford lies Burton-upon-Trent. Burton is world-renowned for its brewing and food-and-beverage industries. On the southern side of Stafford, at Tamworth, there are substantial areas of both distribution and industrial property. Finally, the A50 (which links the M6 Motorway at junction 16 with Derby via the M1 Motorway), passes from west to east across the whole of Staffordshire providing a critical freight route.

Roads are the primary infrastructure. The M6 Motorway and M6 Toll provide north/south routes. The A50 provides east/west routes, and the A38 links Burton to the eastern parts of Staffordshire. For companies wishing to move goods throughout England and Wales, Staffordshire’s motorway locations make it a highly attractive option.

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Warehouse Construction Services

New Build Warehouses

The construction of a new warehouse begins before the first foundation is laid. When we go to the site, we inspect the ground, the access routes and the services, and note any factors that might affect the design or the schedule. Since parts of Staffordshire were historically industrial or mining areas, they must be thoroughly checked before any design work is carried out.
Next is the design and the preparation of a cost estimate. This includes the frame size, the floor slab specifications for racking and vehicles, the height, and the layout of the yard and parking areas. In most warehouses in the UK a steel portal frame is used on a concrete slab; our approach begins from this and is adapted according to the way you will use the building.
The construction proceeds in this sequence: groundworks, then the frame, followed by the roof and cladding, and finally the fit-out and external works. Throughout the process, you work with a single team and have one point of contact, unlike the situation where five contractors blame one another when things go wrong.

Distribution Centres

More consideration is needed for distribution centers than for standard units because mistakes in this area are expensive to correct later. The design is generally determined by the high-bay racking, the height and the distance between the frames being established in relation to the racking and the equipment that is going to run inside it. We look into this with you and your racking supplier at an early stage so that the building will match the operation.
The dock levelers and loading bays must be suitable for your vehicles and the volume of traffic they handle. The number of doors and their positions affect the yard layout and how quickly trucks can be turned around. Our approach is to design the yard with this in mind: taking into account turning circles, parking spaces, and queuing areas. In the case of large operations, which are typical along the M6, it is this level of detail that ensures the site runs at full capacity rather than becoming a bottleneck.
The other major component is the floor slab; because it must carry heavy racking loads and be flat for narrow-aisle trucks, it has to be correct the first time.
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Logistics Facilities

The logistics sector includes cross-docking, parcel hubs and e-commerce fulfilment, each of which has its own requirements.
For cross-docking, it is necessary to have a quick flow of goods, with entrances and the yard arranged so that the goods can move smoothly from one truck to another. In the case of e-commerce and parcel handling, warehouse space is usually combined with mezzanine picking areas, and there is a strong demand for power and data for the conveyors and sorting equipment. If the frame, the floor loadings and the service routes are properly determined at the design stage, the fitting out can then be carried out smoothly later.
The M6 and A50 mean that Staffordshire is a natural base for this type of operation since they serve a wide area of the country.
Automation is nowadays a common feature—this includes automated storage systems, conveyors, and robotic picking systems. Such equipment requires a certain degree of floor flatness, a reliable power supply, and in some cases its own separate foundations. In order to ensure the building is ready for the equipment, we cooperate with the automation suppliers during the design phase.

Manufacturing Facilities

Core work is carried out in Staffordshire since the county has a manufacturing industry. Although manufacturing buildings are similar in structure to warehouses, there are differences in the details. Production lines usually require more power, drainage for the processes, separate areas and floors that are built to accommodate the equipment.
The first step is to understand the process and then design taking that into account. We look at the use of overhead cranes for heavy components, at ventilation and extraction in relation to production, and examine how the materials travel around the site. In the case of manufacturers producing ceramics, food and drink and engineering products, special requirements are common, and we design and build with these in mind from the beginning.
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Warehouse Extensions

Growing a warehouse isn't simply a matter of adding more floor area; the new section has to be integrated into the original structure, match the existing cladding and roof, and be compatible with the existing drainage and access arrangements. Before designing the connection, we assess what the present building can withstand.
The majority of businesses would like to remain open during working hours. In most instances, the warehouse continues to operate. This is due to the need to carry out proper sequencing, to maintain the joint as weathertight, and to keep construction traffic out of the areas where work is being done.
The roof slope, height, framework spacing, and the cladding all have to match so that the extension forms part of the building rather than looks like an awkward addition.

Warehouse Refurbishments

A great deal of our work involves existing buildings, as Staffordshire has a large number of older industrial properties. This refurbishment can involve either specific repairs or a complete strip-back and rebuild of the roof, floor, cladding, services and offices.
Roofs and the external wall coverings are usually dealt with first, particularly in the case of older buildings in which the insulation, weather tightness and fire resistance do not meet the present standards. The floors may require repair, an overlay, or complete replacement, and the services in older buildings are generally undersized or worn out and need to be upgraded before a new tenant takes over.
It is normal to carry out office upgrades, either at Cat A or Cat B level, depending on how far the work is taken. Since we are involved through our sister company, Strip Out Company, we handle the strip-out and demolition ourselves, including surveys and waste removal, so the site is ready before refurbishment begins.

Design and Build

Designing and building involves taking a project from its initial concept through to completion. We begin by determining what you need, then proceed with the design within your actual budget and timetable.
Planning is included in the process. Since Staffordshire has a two-tier system, consisting of the county council and eight district councils, Stoke-on-Trent manages its own planning as a unitary authority. When carrying out the design, we ensure you are working with the correct body for your site and that the Building Regulations are considered from the very beginning, not added at the end.
The cost analysis is carried out concurrently with the design, enabling you to determine the actual cost before making a decision. It's not a price that is reduced once the tenders are received.
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Sectors we construct facilities for:

Logistics/Distribution

Staffordshire’s strategic location at the heart of the UK’s logistics network, both on the M6 (which passes through the county) and on the A50 (the key route to Manchester Airport), means that it provides an excellent base for many national and regional distribution centres. The operational requirements of such logistics/distribution centers include: large clear-span warehousing; a large number of docks (with overhead cranes); and yards that can accommodate continuous vehicle movement. Therefore, our designs reflect how goods move and vehicles operate.

Ceramic/Manufacturing

Stoke-on-Trent was once renowned as ‘The Potteries’ and ceramics remain one of the most significant parts of Staffordshire’s economy today, whether it be traditional ceramic products or advanced materials; or indeed if it be the manufacture of machinery/equipment. Such manufacturing operations require structures that provide resilience against wear and tear; robust construction to withstand considerable loads; substantial floor loadings; and heavy power supplies. Our designs take into account how the operation will run.

Food/Beverage

Burton upon Trent boasts a global reputation as a center for brewing. Food and drink production is another area in which Staffordshire excels economically. It encompasses a wide range of activities, including food production, food packaging, cold storage provision, and distribution. For cold stores, there are specific requirements for insulation levels, flooring, and refrigeration. This contrasts significantly with a typical warehouse. We therefore design these types of buildings around how they are used to operate a food or chilled facility.

E-Commerce/Fulfillment

As a result of its good road connectivity (via the M6), Staffordshire is a prime area for e-commerce and fulfillment. As such, our designs incorporate a mix of warehouse floor space, mezzanine picking areas, automated systems, and higher-than-average power requirements. We create the structural and service framework required to facilitate this from day one.

Manufacturing & Engineering

In addition to ceramics and food processing, Staffordshire also has a diverse engineering sector that requires buildings with greater power supply capacity, specialized services, and floors capable of supporting heavy equipment. From day one, we consider what is necessary when designing and constructing buildings for manufacturing/engineering operations.

Why Staffordshire?

The primary reason for this is the M6, since it is the main motorway connecting the south with the Midlands and the north-west, and therefore places Staffordshire on one of the country's busiest freight routes, with congestion near Birmingham alleviated by the M6 Toll. For a distribution business covering a large area, that situation is difficult to surpass.
The A50 provides an east-west route linking the M6 to the M1 and to Derby, thereby extending the county's reach even further. Taken together, this makes Staffordshire a true crossroads for freight.
The county also possesses a substantial manufacturing industry, including the ceramics produced in Stoke, the brewing carried out in Burton, a wide-ranging engineering sector, and land that is more accessible and less expensive than in the south. There is also some former industrial and mining land that can be put to use, with support for regeneration. The combination of connectivity and industrial heritage found in Staffordshire makes it an attractive option for a business involved in distribution or manufacturing.
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What are the Warehouse Construction Challenges in Staffordshire?

Warehouse construction challenges are found throughout Staffordshire. Most of the competition will not address the warehouse construction challenges below; however, each challenge affects every project.

Historic industrial and mining legacies exist in parts of Staffordshire, particularly around Stoke and in the former coalfield regions. In some of these locations, contaminants, underground working, or buried foundations may be present at sites. Proper investigations to develop designs should occur prior to construction.

Limited availability of logistics land, along with high prices for this type of land, especially when located near the M6 highway. When good-quality logistics land becomes available, it is quickly taken by others, potentially increasing both the time and cost to complete the project.

Planned development in Staffordshire involves two local authorities: Staffordshire County Council and seven district councils. Additionally, Stoke-on-Trent operates as a Unitary Authority. Determining which local authority jurisdiction you operate within is critical from the outset of a project.

Some areas of Staffordshire include green belt designation and rural area classification. For example, in northern Staffordshire, the Peak District National Park exists and therefore limits the types of projects that can occur in this region. Understanding whether a project location falls within a green belt or rural classification is important for determining potential limitations and/or constraints on development.

Flooding or drainage issues related to nearby waterways, such as the River Trent, also exist in some parts of the county. Projects that have been identified as being located in a designated flood zone may require additional considerations and design requirements to accommodate the increased risk associated with flooding.

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Our Construction Capabilities

Everything needed to deliver a warehouse start to finish:
  • Steel frame
  • Reinforced concrete works
  • Groundworks and foundations
  • Cladding
  • Roofing
  • Office fit-out
  • Loading docks and dock levelers
  • Service yards and external works
  • Drainage
  • Mezzanine floors
  • Fire protection
  • Warehouse flooring, including high-spec slabs for racking and equipment loads
Since it's all managed by a single team, we carry out the steps in the correct order and make the changes as we build; this avoids delays that would occur if we were dealing with multiple contractors.

FAQ

What areas do you cover in Staffordshire?

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We build across Staffordshire, including Stoke-on-Trent, Stafford, Burton upon Trent, Tamworth, Cannock, Lichfield, Newcastle-under-Lyme, Leek, Rugeley, Uttoxeter and Burntwood, plus the surrounding areas served by the M6, M6 Toll, A50 and A38.

What is the cost of Building a Warehouse?

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Warehouse construction costs vary based on the size of the space, specifications, and location. In addition, different soil types may pose challenges for construction. Therefore, a specific price for a project cannot be provided. An accurate estimate will depend on a site visit and a discussion of the project requirements.

How much time do you need to build a warehouse?

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This also varies. The time required to complete a project varies depending on its type and size. For example, the time required to construct a simple new warehouse would be several months from the completion of the groundwork to the delivery of the key. Planning and design are usually completed before construction begins.

Will I need planning permission for my warehouse?

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Typically, yes; however, certain small projects or alterations that use a warehouse differently than originally intended may qualify as permitted development if they meet the criteria defined in local zoning ordinances. Depending on the area where your property is located, different authorities govern these matters. In Staffordshire, planning is handled by district councils, with Stoke-on-Trent being its own unitary authority. We assist clients through the process of determining feasibility and obtaining approval

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