Willmott Dixon Construction awarded this £1.85m value project to Stephenson on behalf of their client, South Wales Police, to construct the reinforced concrete frame for a new Police Learning Centre in Bridgend. The building consists of two adjacent frames each with four suspended slabs and a central steel beam atrium connection. The works were divided over 3 phases which included large radius slabs and walls, all specific to plain finish. The sample finish was elected by the client from the works undertaken by Stephenson on the Rhiw Car Park, Bridgend.
The project was undertaken during the pandemic and subsequent lockdown period which presented a multitude of issues including changes in large parts of our process and procedures, supply chain, health and safety and on-site interactions. Initially, the project start date was delayed due to an issue with the erection of the Tower Crane and as a result, the works started with the use of a mobile. Once mobilised and works were underway, the site team quickly adapted to the new circumstances and progressed as per programme. In light of the new situation, Stephenson operatives presented themselves to the highest standard throughout, which was evident with feedback from the Willmott Dixon team and our EHS audit results.
The Project Team
Chris Purchase - Operations Manager at Willmott Dixon
John Coalter - Building Manager at Willmott Dixon
Sean Delaney - Site Safety Officer at Willmott Dixon
John Pitea - Contracts Manager at Stephenson
David Edwards - Project Manager at Stephenson
Wayne Bowler - Site Manager at Stephenson
Evan Denscombe - Site Engineer at Stephenson
Methodology
An Ischebeck titan falsework system was opted for the construction of the suspended slabs. This allowed the flexibility to ensure the demands of the project were met.
As the soffits were to remain exposed, Stephenson consulted with the supply chain to ensure the optimum results were achieved and the correct selection of materials were sought. Through this consultation process, Pourform ply was determined as the most appropriate product to provide the level of consistency set out in the brief. Paslode finishing nail guns were purchased to lessen the visual impact left from nails as well as extensive research by Stephenson to determine which release agents would deliver the best outcome. Optimum SE was presented to Stephenson by one of our suppliers as it was often used in the production of special finish concrete construction which was then subsequently used in all concrete elements. One thing noted from the use of this product was the residue left once struck that required cleaning. To do this, we experimented with the use of a sanding giraffe and after a sample area proved positive, this technique was applied to many areas.
At the request of Willmott Dixon, Stephenson were asked to provide an anti-dust concrete release agent to be applied to the newly laid concrete slab surface. After substantial researching, our procurement team were able to find a suitable product which was the used throughout the complete project.
Framax Doka panels lined with an Ultraform plyboard were utilised for the construction of the vertical elements of the build. This proved effective in producing the high standard finish witnessed throughout the project.
Tarmac were the preferred supplier for the concrete provided at South Wales Police Learning Centre and provided mix designs for both 32/40 and 28/35 (S3). During the project, a further 28/35 (S4) mix design was requested to improve the flow of the concrete to specific vertical elements.
Reinforcement was installed by Eagle fixing, who utilised fixing guns to tie the steel. The operatives provided are a testament to Fadhil and the level of workmanship they produced.
The reinforcement (approximately 400t) was supplied by Roe Group, Pump Wright provided the concrete pumps for slab pours between 110-150 m³, GPR was supplied by Fibregrid and Precon provided the shear rails requirements.
Willmott Dixon Testimonial
"A promise was made at the start of this contract the the level of finish we required would be achieved so 'don't worry'. All too often in this industry we 'over promise' and under-deliver, but in this instance, Stephenson didn't - they did and have made good promise on that.
Dave (David Edwards) and his team have been a pleasure to work with. Nothing has been too much trouble and any issues have been addresses in friendly amicable manor and as such no discussions have been uncomfortable or left un-resolved.
In whole, Stephenson have been a true 'Cat A' supply chain partner who do embrace the Willmott Dixon ethos and I, personally don't say that lightly.
The level of workmanship afforded to us has, in no short part, convinced us and our customer to utilise the concrete frame build ethos on the up and coming gymnasium building, high accolade to say the least.
From the top down, it has been an honour to work with Stephenson, so from the site team, 'thank you'."
~ Chris Purchase - Operations Manager at Willmott Dixon
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