© David Stewart Photos

ASRS and LOC Buildings for Jaguar Land Rover – Structural EngineeringCastle Bromwich

Large new logistics buildings in Castle Bromwich with long spans.

Jaguar Land Rover needed to expand their logistics capacity at the Castle Bromwich plant for the storage of car parts to feed the production lines. The adjacent site, previously owned by Dunlop Motor Sports, was acquired for this expansion. This provided space to construct two large stores buildings.

The ASRS Building houses the 20m tall Automated Storage and Retrieval System, offices and amenity areas. The LOC is the Logistics & Operations Centre which houses traditional storage racking together with further offices and amenity areas. The B-Block Link Canopy provided an enclosed route between the new stores buildings and the adjacent production buildings. The buildings are serviced by external canopies for unloading HGVs and large areas of concrete hard standing are used for HGV trailer parks.

Ridge provided a multidiscipline design team and worked with JLR to develop the concept design to tender stage. We were novated to the Design and Build Contractor and completed the full detailed design of all structural elements.

  • 25,000sqm

    Floorspace for Logistic Operations

  • £35million

    Construction value

  • 50m Clear Span / 25m High

    Portal frames

Structural Design
The new buildings are steel portal frames supported on pad foundations. Vibo stone columns were used to increase the bearing capacity of the underlying soils which allowed us to eliminate the need for concrete piles saving JLR time and money. Ground improvement using lime stabilisation of the demolition arisings was designed to provide an adequate foundation for the ground bearing slabs.

The ASRS system required a very large column free space. We designed the 25m high portal frame to span 50m over the ASRS using the largest available universal beam sections. Fibre reinforcement technology was used in the ground bearing slab in this area to provide a 50x50m single pour without joints.

In the LOC we minimised the number of columns by using a hit and miss design with transfer beams. This maximised the usable floor space available to JLR and reduced the limitations on racking layouts.

Both buildings featured hipped gables which improves the aesthetics and provides a continuous parapet allowing safe access for maintenance.