Building

We build a range of structures in the many sectors that civil engineering comes into contact with.

Our expertise includes the construction of buildings for municipal, commercial, industrial and private customers seeking intelligent, value-engineered solutions.

We provide a proactive approach and quality of service that sees a volume of repeat business, such as the four projects we have completed for the Maritime and Coastguard Agency (MCA).

Kingwood Stud Horse Training Facility
Kingwood Stud Horse Training Facility

Kingwood Stud Horse Training Facility

Kingwood Stud Horse Training Facility
Customer: Kurt Systems (UK) Ltd
Value: £4.7m

The project comprised the construction of a unique Horse Training Facility at Kingwood Stud, Lambourn.

Our customer, Kurt Systems (UK) Ltd has revolutionised the way young racehorses are prepared for training. The facility comprises a 1.2km oval track covered by a steel frame and roof cladding. A monorail is hung from the steel frame with five horse cabins and an operator’s cabin all linked together to form a train. The train does not push or pull the horses, it merely encourages them to move at the desired pace round the track.

As Principal Contractor, our works involved a cut and fill operation to moderate the track gradient with a 2.5m deep cut at one end of the track and the excavated material used to raise the track above ground level at the opposite end. Land drains were laid under the track formation to intercept surface water running into the cutting and discharge it to a soak away trench.

All surplus excavated material was reused at the low end of the track to raise the central area to track level. The track formation was stabilised with a proprietary binder material mixed into the existing subsoil and the track bed was formed using a Type 3 material to facilitate drainage under the equestrian surfacing, which was retained with timber edgings.

Approximately 400 concrete pad foundations and bolt sets were installed to fix the steel portals supporting the roof and monorail system. We also managed the delivery, installation and commissioning of the monorail system and the operator and horse cabins which were carried out by specialist contractors from the UK and Germany.

The system is powered by electricity which required the installation of a new electrical substation. This was installed after first diverting an existing overhead HV line into an underground route, crossing one end of the track. These diversion works were carried out at the commencement of the contract to eliminate the risk of working near overhead cables. The electrical works, which also included track lighting, were carried out as a contractor’s design portion of the project.

The site was extensively landscaped to comply with the planning consent. The central area of the track was returned to lush paddocks for the horses, divided by three-rail timber fencing, backed by hawthorn hedging to match the remainder of the stud farm. A significant number of trees were also planted around the inside and outside perimeter of the track to help screen the development. The roof cladding also consisted of three shades of green to help blend the new facility in with the surrounding landscape.


MCA Projects
MCA Projects

MCA Daedalus Safety Training Hub

MCA Centre Projects
Customer: Maritime & Coastguard Agency
Value: £9.2m

Raymond Brown Construction has undertaken four projects for the Maritime & Coastguard Agency:

A state of the art robust commercial multi-disciplined building and civils infrastructure at MCA Daedalus, Lee-On-Solent, this project comprised the construction of a new helicopter hangar facility and associated accommodation and maintenance facilities. In addition to this we were recently appointed to construct a purpose built Coastal Safety Training Hub and a Coastguard Rescue Station at the site.

At MCA Portland, we constructed a 2,000m2 hangar, workshops, office accommodation, mess facilities, fire-tender building and associated external works, including realignment of existing runway.

At MCA Highcliffe, we constructed a new two-storey centre at MCA Highcliffe. Features comprised steel frame structure, Kalzip roofing system, silicone glazing system, and Gustaf panelling.
North Farm Depot
North Farm Depot

North Farm Depot

North Farm Depot
Customer: Tunbridge Wells Borough Council
Value: £4.8m

The design and construction of a new storage and operations depot which included, construction of buildings, office space, workshops, external yard and reinforced concrete slabs, drainage, and a new private access road.

Works included the management and coordination of our supply chain to construct the steel framed structure, cladding, piling and specialist M&E fit-out works whilst tying into the adjacent hard landscaping, roadworks and connections to adjacent landowners properties. The works also saw the diversion and re-routing of statutory utilities as well as the supplies to the new structure itself.
Mountbatten Tennis
Mountbatten Tennis

Mountbatten Tennis Centre

Mountbatten Indoor Tennis Centre
Customer: Portsmouth City Council
Value: £1m

Raymond Brown undertook the design and construction of this new 67m x 40m indoor tennis centre. The new facility comprised a framed, fabric covered clear span steel structure to accommodate 4 indoor tennis courts, associated external works, ancillary accommodation and service connections which linked to the existing gymnastics centre via a new covered walkway.

The works comprised all necessary enabling works and CFA piled foundations. The fabric covered clear span steel structure comprising 12 hollowed lattice arches, each weighing 2.5 tonnes. We also laid a porous asphalt surface and provided court markings, court backdrops, court dividers, court nets and posts.
CLM Facility
CLM Facility

CLM Facility

CLM Manufacturing Facility, Hythe
Customer: Geo Speciality Chemicals UK Ltd
Value: £3.2m

This project was to construct a new production facility at GEO Specialty Chemicals UK, Hythe site. An important part of this development was the construction and fit-out of a CLMMF (Contact Lens Material Manufacturing Facility) building, flammable storage tank farm and access roadways.

The new building was constructed partly on an existing ‘brown field’ location and partly on adjacent development land, which required a ‘cut and fill’ operation.

The building comprises a piled, heavy duty concrete slab, a steel portal frame with brick and block infill and aluminium polyester profile sheet roofing.

An external concrete bunded tank farm for flammable material storage and a tanker unloading facility was constructed on piled foundations adjacent to the building with paving and roadways constructed around the building for both vehicular and pedestrian access.
Tilmanstone Salads - Project Brazil
Project Brazil Tilmanstone Salads

Project Brazil Tilmanstone Salads

Project Brazil Tilmanstone Salads
Customer: Bakkavor Tilmanstone Salads Value: £0.43m

This project was to design and construct two extensions to a food processing and packing facility in Dover, Kent. Tilmanstone Salads are one of the UK's leading salad suppliers and are partners with the top global grocery retailers.

The first extension was required to house a new salad processing facility with significant challenges set by the customer at project outset including achievement of a tight programme and construction methodology to mitigate disruption to the existing production facility.

The extension required knocking through into the existing factory without affecting the 24 hour salad production, which was successfully overcome with close liaison with the customer team, regular inspections by the food hygiene team and double shrouding of the working areas.

The project also had to be delivered within a very short timescale; ten weeks to carry out detailed design, install drainage, form the concrete substructure and erect and clad the steel frame. Working longer shifts and weekends, the project was delivered three days early.

The second extension was for the design and erection of a workshop adjacent to the loading bays for cleaning and storing the high tech salad carts, with the added difficulty of casting a floating floor over an existing interceptor, which only became apparent during site clearance activities.

The construction of the workshop consisted of a traditional steel frame and cladding, together with construction of a brickwork retaining wall allowing drivers access to the logistics office located internally in the corner of the new structure. Internal temperature control was moderated with the installation of time release door closures to all fixed and rapid rise doorways in the main packaging areas.

External finishes such as footpaths, external drainage and soft landscaping were all completed within programme.
Smurfit Kappa Paper Mill
Smurfit Kappa Paper Mill

Smurfit Kappa Paper Mill

Smurfit Kappa Paper Mill
Customer: Smurfit Kappa Townsend Hook
Value: £5.5m in two phases

Phase 1

Raymond Brown was originally awarded a £1.1m package to construct pile caps for the PM9 Paper Machine Building and auxiliary buildings for Smurfit Kappa in Snodland, Kent. The project included a stock preparation building, control building and a roller transport tunnel from the building to the existing warehouse.

As Principal Contractor, we commenced a demanding 21 week construction programme . The first section of the 150m long paper machine foundation, a 300m³ concrete pour and a three tonne bolt cluster, (set to a tolerance of 3mm complete), and the construction of the 200 pile caps progressed at a pace and was completed ahead of schedule.

Phase 2

This £4.4m phase was bid and negotiated mainly due to the successful delivery of the Phase 1 works, where RBC demonstrated to the customer that by working with them to mitigate their delay issues we could deliver a quality product to time and budget.

Phase two of the project included the new paper machine foundations, floor slabs at varying levels, plant and equipment foundations on all floors, together with the adjacent reinforced concrete stock preparation building.

The logistics along with the detailed design being delivered on a just in time basis were challenging, but by maintaining our flexible approach and good communications we maintained excellent relationship with all contractors on site.

Installation of precast concrete panels, exterior cladding and roofing in advance of our works did result in limiting our access routes and methods to deliver the works, however with good programme management and regular site co-ordination meetings we ensured that all contractual dates were met.

KEY CONTACTS

Southern and South West
John Laker
E: john.laker@rbconstruction.co.uk
M: 07900 210 649

South East
Frank Fealey
E: frank.fealey@rbconstruction.co.uk
M: 07796 302 158

Wales
Kelly Meredith-Jones
E: kelly.meredith-jones@rbconstruction.co.uk
M: 07855 518 652