Fosroc Expandite - is one of the largest manufacturers of construction and civil engineering products in the world.

the brief - after the merger between Fosroc and Expandite the joint operation had main warehousing facilities at Tamworth and Greenford, with a smaller warehouse at St Helens. As a result of a logistics structure review, the client decided to rationalise the warehousing facilities by centralising and consolidating all finished goods in a single facility on their production site in Tamworth. It was agreed that the best approach to producing a building which would efficiently meet their requirement was to design the facility "from the inside out".

the approach - due to the sensitive nature and possible closure of warehousing it was important to keep the study confidential. We commenced the project with a feasibility study into various configuration options. As the client had available land to build the new warehouse, a study into the location was not needed and this meant that we could start calculating the required size immediately. We analysed stock and activity data from the three warehousing locations to work out the site size needed in conjunction with the proposed layouts. After the decision on the favoured design had been made, we developed the option to the level where the scheme could be put-out to a design and build organisation for tendering. During this stage we produced detailed analysis of proposed floor space, equipment requirements and pallet racking locations. Another aspect of the project was the production of staffing requirements together with a staff structure diagram.

the result - we reduced the floor space from the three combined units of 80,000 sq ft to 50,000 sq ft in the new single distribution centre by removing duplication of stock and improving operating techniques. Also we reduced the staffing levels and costs by 30%. Both of which resulted in a considerable saving for our client.

They retained trade counters with minimal stock holdings at the old sites but closed the major storage facilities. Due to its central location, the new warehouse provides consistent, accurate delivery throughout mainland UK within 3-4 working days from receipt of order.

Building 243, University Campus, Cranfield, Bedford, MK43 0AL, UK
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