Warehouse Drain repairs

Project Overview

Civils and Environmental Ltd were appointed to undertake the replacement of 56 linear metres of internal ACO channel drainage within an operational warehouse facility in Crewe. The works were scheduled during a planned 5-day shutdown period to ensure safe working conditions and prevent disruption to warehouse operations.

The project involved removing existing deteriorated drainage channels and installing chemical-resistant 100mm channel drainage systems with stainless steel gratings, reinstated with fibre-reinforced concrete (FTC concrete) to provide long-term durability in an industrial environment.

Site Assessment & Pre-Construction Planning

Prior to works commencing, a full site review and risk assessment were carried out. Key considerations included:

• The works being undertaken inside a warehouse environment

• Presence of dust hazards

• Possible chemical contamination within existing drainage channels

• Requirement for full site shutdown

• No forklift or staff movement permitted during works

• Site induction and full PPE mandatory

A controlled methodology was developed to ensure:

✔ Safe containment of dust
✔ Protection from chemical exposure
✔ Compliance with internal site procedures
✔ Completion within strict shutdown timeframe

Although a CAT scan was not completed, existing service routes were carefully considered during planning, and cutting works were controlled around known drainage positions.

Controlled Work Area Setup

To maintain a safe and compliant working environment, the team implemented:

• A fully tented working enclosure inside the warehouse

• Industrial dust extraction systems

• 110v electric saws with diamond blades (to reduce fumes)

• Mechanical breakers for controlled removal

• Chemical-appropriate PPE for operatives

This containment approach ensured airborne particles were managed effectively — particularly important in a food, logistics, or sensitive storage environment.

Drainage Removal & Replacement Process

1. Existing Channel Removal

• Precise saw-cutting around the perimeter of existing channel drainage

• Controlled breakout of surrounding concrete

• Careful removal of degraded channel systems

• Segregation and compliant disposal of demolition waste

2. Sub-Base Preparation

• Cleaning and preparation of the trench base

• Ensuring correct falls and alignment for optimal water flow

• Inspection for any substrate defects before reinstatement

3. Installation of New ACO Channel Drainage

The new system consisted of:

• 100mm chemical-resistant channel units

• Stainless steel channel gratings

• Designed to withstand industrial traffic and chemical exposure

Two specification options were priced:

• Option 1: Full chemical-resistant channel system with stainless steel grating

• Option 2: Stainless steel grating with chemical-resistant channel (alternative cost option)

Channels were precisely levelled to maintain drainage performance and prevent standing water within the warehouse.

Concrete Reinstatement

Following installation:

• Channels were haunched and secured using FTC (Fibre-Reinforced) Concrete

• Reinforcement improves crack resistance and load durability

• Surface finished flush with warehouse floor slab

• Final curing time allowed within shutdown schedule

This ensures the new drainage integrates seamlessly into the operational floor while maintaining structural integrity for forklift loads once operations resume.

Health, Safety & Environmental Controls

Given the operational warehouse setting, strict measures included:

• Full PPE compliance

• Dust extraction during cutting

• Controlled demolition techniques

• Waste segregation and licensed disposal

• Site fully non-operational during works

This controlled delivery minimised risk to client staff, protected stored materials, and maintained regulatory compliance.

Project Programme

• Works completed during a 5-day scheduled shutdown

• Full mobilisation, installation, and reinstatement achieved within agreed timeframe

• Site handed back clean, compliant, and operationally ready

Outcome & Client Benefits

✔ Replacement of failing internal drainage infrastructure
✔ Improved chemical resistance within warehouse environment
✔ Durable stainless steel gratings suitable for industrial traffic
✔ Reduced risk of standing water and contamination
✔ Completion within strict shutdown programme

The project demonstrates Civils and Environmental Ltd’s ability to deliver specialist internal drainage replacement works within live industrial environments, combining precise cutting, controlled dust management, compliant waste handling, and durable reinstatement.