Croylek (Phases 1 & 2)

Design & Build Extension & Refurbishment of Manufacturing Unit

Project Details


Coulsden, Surrey


Croylek Limited

Project Manager

Baxall Construction



Baxall Delivery

Team 2

Programme Period

26 Weeks

Contract Value


Following the successful delivery of a previous contract for client Croylek, Baxall were instructed to carry out a new design and build extension and refurbishment development to their 1960s concrete- framed manufacturing depots in Coulsden, Surrey. The works comprised two main phases across the company’s two adjacent operational buildings.

Essentially the company required additional space to increase storage capacity without having to relocate the business. The initial plan was to solely extend the side of the first building (Phase 1) into the operational yard although upon review, the team identified that a steel frame extension could also be added to the rear and the height of the building raised, thus creating at least twice as much usable space.

Phase 2 encompassed a similar approach with the addition of an industrial concrete load bearing mezzanine floor for future production space which in turn, tripled the manufacturing floor space capacity. The works were completed with the full refurbishment of the offices, installation of new double glazed windows and an insulated cladding system on the front of the buildings, thus giving an overall more energy efficient, modern and aesthetically pleasing appearance.

The two phases of works took place while the client remained in occupation with both the manufacturing floor and offices fully operational. This necessitated extensive safety reviews, assessments and plans with review on a regular basis and the compilation of bespoke method statements in close consultation with the client to ensure that safety was maximised at all times and disruption minimised. The supply chain were hand-picked based upon their experience of delivering similar precision works and technical ability, thus ensuring the client received the best professional team and expertise bespoke to their requirements.

Communication was maintained on a daily basis between the Site Manager and client and a proactive approach promoted where disruptive works were pre-warned and arrangements made to accommodate. The team offered full flexibility to the client and employees with regard to planning and rescheduling works to enable the business to continually operate, for example, utilising weekends to carry out works such as the roof demolition and scaffold erection. Similarly, deliveries and site traffic were carefully co-ordinated giving consideration to the Croylek staff access requirements and the busy surrounding estate roads. The Baxall team further worked with local stakeholders including neighbouring businesses on the industrial estate both forewarning of the works programme and providing verbal and printed updates throughout the works period.

The contract was delivered safely, on time and budget.

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