2020Case13 JohnPaulConstruction

Contents Lean Construction Ireland Annual Book of Cases 2020 51 Case 13 Scope of Works The works comprised the construction of: • A new build high-bay warehouse building with a gross floor area (GFA) of 58,032 m2, including: Warehouse element maximum parapet ridge height of c.17.9m and overall dimensions of c.124m in width and c.437 in length. 20,068m2 of temperature-controlled storage chabers, ranging from a 4,300m2 “-24o freezer” to a 6,000m2 fruit and vegetable storage facility. High bay and dynamic racking to “ambient” cross- dock warehouse space. Associated mechanical and electrical services. Two high-specification finished administration buildings (1,790m2 GFA and roof height of c.10.6m). 154 Dock Levellers. • Earthworks enabling package: 370,000m3 bulk earthworks. 330,000m3 lime and cement stabilisation. 4.2km Tubosider drainage system (1400mm diameter). • 80,000 m2 of external concrete truck parking and services yards. • 300 car parking spaces. • Largest building-mounted photovoltaic array in Ireland comprising 4,364 panels capable of generating over 1-million kWh hours per annum. Works were scheduled to commence in September 2018, and the brief called for the facility to be delivered by October 2019 to meet peak Christmas demand and provide appropriate additional warehousing space for Lidl to store stock in order to address uncertain Brexit outcomes. Across four areas – Groundworks, Facilities, pecification, and Sustainability – the programme targeted delivering: • Groundworks: An engineered design and build ground treatment solution toprovidea suitableplatformona sitewith poor natural ground conditions to construct the warehouse. • Facilities: A curtailed transition period between construction and operations by integrating Lidl IT, its network and order picking systems, as well as mechanical handling equipment deliveries into the main build programme. • Specification:A“headoffice”specificationadministration block for staff and a warehouse building that met Lidl International design standards. • Sustainability: One of the most sustainable and energy- efficient logistics centres in Europe with A1 energy rating and BREEAM Excellent Standards in design and construction. Projects of scale, with many duplicated details, demand a productionmindset to deliver consistency and avoid rework, and thus a Lean approach is tailor-made for this kind of project. The strategy deployed by John Paul Construction during early planning was to explore and deliver on mar- ginal gains in every work package, and to understand and mitigate project risk through careful planning and contin- gency planning. From early planning stages during the tender, technical and commercial risks and opportunities were identified and recorded in live registers from detailed interrogation of the works requirements, multiple visits to recently completed RDCs in the UK, and knowledge sharing with supply chain partners, many of whom had worked on similar Lidl Projects in the UK and Europe. Ultimately Lidl would have the final say in relation to all initiatives identified; however, the following schedule identifies some of the technical efficiencies delivered by our Project Team through deployment of Lean thinking from the outset: • Project acceleration to mitigate delays incurred pre-commencement on-site. • Groundwork strategy that eliminated off-site disposal in favour of treatment and reuse on-site. • Overall review and redesign of drainage, foundations, structural steel, and roofing to reduce quantities, improve installation efficiencies, and provide an overall cost and programme benefit to the project. • Early selection of pre-lagging mechanical and refriger- ation pipework, and off-site lagging of refrigeration plant, significantly reduced the typical refrigeration commissioning periods. • Increased off-site assembly of electrical, mechanical, and sprinkler components to accelerate first-fix works. • Utilising pre-fabrication for walls and buildings where possible to improve installation times. Figure 1. “One Project Approach”

RkJQdWJsaXNoZXIy MTIzMTIxMw==