Portwest, the world’s fastest-growing workwear company, partnered with us to embark on a major expansion of their warehouse in Thurnscoe, South Yorkshire. This project marked the continuation of a successful partnership between us, secured through a competitive tender process. 

The challenge

As a leading designer, manufacturer and distributor of protective workwear and PPE, Portwest’s exponential growth required a larger, state-of-the-art warehouse facility. 

The challenge was to wrap the new warehouse around an existing one, forming an L-shape upon completion and making the extension height taller than the existing one to incorporate automated racking. To achieve this, and for the existing warehouse to continue operating, a 15-metre-high fire and weatherproof wall was erected, incorporating part of the old warehouse into the new footprint.

The outcome

The expanded warehouse boasts an impressive 8,000 square metre floor area with a 23-metre ridge height. Seamlessly integrating the steel frame and cladding between the old and new structures required 3D modelling and close collaboration between all parties.

The project’s success stands as testament to the collaborative effort involved. The larger warehouse has increased capacity and significantly improved efficiency. Streamlined workflows, optimised inventory and reduced lead times have bolstered Portwest’s ability to meet growing global demand for their products, leading to reduced costs and heightened customer satisfaction. 

The partnership between our team, Portwest, Simpsons of York and Orchard Surveying showcased our commitment to innovation and expertise executing complex projects. 

The hurdles we overcame

Overall, integrating the old and new structures with minimal disruption highlighted our skills in balancing logistics requirements with environmental considerations. During the planning application phase, we had to negotiate with The Land Trust to offset the loss of some biodiversity on the adjacent land. Through collaborative efforts, it was agreed that planting initiatives would be employed to offset any such loss ensuring that the project remained in harmony with the local ecosystem.  This enabled Portwest to uphold their commitment to sustainability whilst pursuing operational excellence.

With a global workforce of over 5,100 employees, Portwest now possesses a logistics facility that mirrors their forward-thinking vision.

If you’re looking for advice or assistance with making alterations to your workspace or home, contact our specialist team of architects who will be happy to help angus.ellis@waltonhorsfall.co.uk or 01484 602377

Photo by Portwest