Phased removal and reinstallation of approximately 136 linear metres of failed surface-water drainage across eight defined work areas at an operational pharmaceutical distribution centre. The site stays live throughout — every method, sequence and control in this document is engineered to keep yards open while we put the new system in.
Eight zones. One operational yard. Zero closure. The work is choreographed around HGV movements, not the other way round — Saturdays and Sundays for breakout and pours, weekday afternoons reserved for cure inspections and finishing.
Project particulars, the parties involved and the assumed scope. This is the contract of certainty before any tooling enters the yard — read once, agreed, signed.
Two parallel narratives: the construction works on one side, the live operation of the distribution centre on the other. They never collide because we engineer them not to.
Saw-cutting and breakout of existing reinforced concrete; removal of failed ACO units; excavation to formation; installation of ACO S150; doweled slab interfaces; reinforced concrete reinstatement in C40/50 rapid-cure; phased curing and reopening.
Vehicle access continuous. Emergency routes preserved. No yard fully closed at any point. Phased working with strict segregation between construction zones and operational traffic — supervised and signed off before each release.
Continuous access for delivery vehicles is maintained at all times.
Emergency access kept clear and unobstructed throughout the programme.
One area live at a time (max two if safe and agreed) — no full yard closure.
Heras + Chapter 8 between construction zone and operational traffic, end-to-end.
CDM 2015 duty allocation, written down so it cannot be assumed. Built AI brings the works package; the client brings the site rules; both meet at the supervisor's desk every morning.
The 136 linear metres are divided into eight independently sequenced areas across the Fuel Yard, Service Yard and Rear Shutter / Dispatch zones. Each zone runs the same seven-step micro-programme; the macro-programme stitches them together.
Primary construction on Saturdays and Sundays (out-of-hours). Supplementary tasks weekdays after 14:00 only.
No disruptive excavation or major concrete pours during peak operational hours. High-noise activity stays on the weekend.
Mobilisation Friday 14 March 2026 — welfare, plant and laydown only. From the following weekend, the rhythm settles in: weekends do the heavy work, weekday afternoons handle the quiet preparation between pours.
No intrusive works on day one
Everything that goes into the trench, the slab and the laydown. Standards, sources and storage all named — to BS EN 1433, manufacturer guidance and project specification.
Inspected before delivery, certified, operated only by trained and competent personnel. Daily check sheets maintained; nothing left running unattended; everything immobilised at end of shift.
Breaker attachment for controlled concrete breakout, bucket for excavation and material handling. CPCS/NPORS-trained operator only. Daily inspection log. No persons within swing radius.
Floor saw for full-depth slab cuts; hand-held for edges and detail. Water suppression for dust control mandatory. Pre-use inspection, exclusion zone, hearing/eye/RPE.
Controlled concrete breakout within saw-cut limits. Noise managed.
Sub-base preparation in layers ≤150mm; verified with laser level.
Concrete consolidation at pour. Works alongside power float (if used).
Channel alignment, falls and finished slab level verification.
Temporary trafficking over poured zones during cure.
Segregation, exclusion zones and pedestrian diversion.
Certified, for grates and channel sections. Manual aids in support.
First aid, eye-wash, fire extinguishers, hand-wash and PPE store.
The macro-sequence followed in every one of the eight zones. No step starts until the supervisor has signed off the previous one.
SMSTS-supervised, briefed daily, signed off in stages. Each procedure has a clear objective, a numbered method, and the critical control note that must hold true before progressing.
No works commence until supervisor signs off safe setup.
Barriers remain in place during curing where required.
Operatives in eye / hearing / respiratory protection as required.
Banksman controls all plant movement.
No installation proceeds until formation is approved.
Installation in accordance with manufacturer guidance.
Supervisor inspection prior to concrete pour.
Concrete cube samples taken per pour.
Minimum 24–48 hours cure prior to traffic, subject to confirmation.
Sign-off entered into the QA pack before progression.
Every pour gets a slump test and a cube. Every zone gets a supervisor pre-pour checklist. Every reopening is signed for. The QA pack lands with the client at completion — concrete cube certificates, pour records, photographic record, marked-up drawing.
CDM 2015. Health & Safety at Work Act 1974. HSE guidance. Site rules. Built AI internal procedures. Then the specific controls that matter for this scope: dust, noise, plant, manual handling, concrete, fuel and weather.
All operatives inducted before works. Daily task-specific toolbox talks. RAMS briefed and signed by all operatives. Supervisor confirms understanding of live-traffic risk.
Heras + Chapter 8. Cones for plant routes. Pedestrian diversions. Dedicated banksman. No open excavations unprotected. Road plates where required.
CPCS/NPORS operators only. Daily inspection logs. Banksman for restricted-visibility movements. Plant immobilised end-of-shift; no plant left running unattended.
Mechanical aids first. Team lifting for awkward items. Lifting keys for grates. Manual handling training; avoid twisting and unsafe postures.
Resin handled with gloves; COSHH on file. Skin contact avoided through PPE; eye-wash in welfare. Spill kits for fuel and chemicals.
Wet cutting. RPE where required. Controlled cutting to minimise dust. Damp-down housekeeping; no dry sweeping.
High-noise work confined to weekends where practicable. Hearing protection mandatory. Plant maintained; idling minimised.
Excavation limited to channel width. No entry into unsupported excavation. Edges protected; no undermining of adjacent slab.
Extinguishers in laydown. Fuel in bunded container. No hot works without permit. Waste segregated; concrete washout controlled; no discharge to drains.
Completion is not "last pour cured". Completion is final walkover, snags closed, QA pack delivered, laydown reinstated, ground checked, sign-off in writing.
Likelihood × severity, before and after controls. Dynamic risk assessment runs daily; this register is the baseline, reviewed if conditions change.
Conclusion. After implementation of the listed controls, residual risks reduce to low or medium. Dynamic risk assessment is undertaken daily; this register is reviewed if site conditions change.
No operative starts work without attending the briefing, agreeing the safe system of work and signing this record. Failure to comply is grounds for removal from site.
This RAMS briefing was delivered in full and all operatives confirmed understanding of the content.
Apex Facilities Group representative — area release and sign-off.