Get in touch
Menu
Close
Let’s work
together.
Get in touch
Nestlé Waters, the water division of Nestlé Group, sought to extend its existing production facility to create additional warehousing capacity and a large lorry park, forming part of a wider programme to introduce a fully automated distribution centre. Working under an EPC contractor responsible for the overall scheme, McCoy were appointed to undertake the earthworks, civil engineering and structural extension of the existing building, forming the basis for the next phase of Nestlé’s operations.
The project demanded extensive excavation and material management, with approximately 100,000 tonnes of material removed to achieve the required reduced levels. Rather than exporting this material, McCoy processed it on site to maximise sustainability and efficiency.
The excavated rock and soils were repurposed as structural fill, converted into high‑performance aggregates for the new lorry park and shaped into screening mounds to support the site’s landscape and acoustic strategy.
This approach not only reduced vehicle movements and environmental impact but also ensured that the new distribution facility was built on a robust, engineered platform capable of supporting heavy logistics operations.
Scope of Works
McCoy’s scope of works included:
Steel Portal Frame Construction
A key structural element of the scheme involved linking the existing warehouse to the new automated facility through a steel portal‑frame extension. McCoy were responsible for both the design and construction of this new structure, ensuring seamless integration between the two operational zones.
Alongside this, the team delivered a range of supporting civil engineering features across the site, including extensive ducting installations, gabion retaining walls to manage level changes and in‑situ concrete staircases that provided durable, long‑term access solutions. These components played an essential role in shaping a cohesive, fully functional logistics environment
Drainage Installation
Given the site’s location in an area known for high rainfall, the drainage strategy formed a critical part of the works. McCoy installed a comprehensive system designed to manage significant surface water volumes, incorporating linear drainage channels, three large interceptor tanks, extensive attenuation pipework and the enlargement of an existing pond to increase on‑site water storage capacity. This infrastructure was essential to safeguarding the new facility and surrounding environment, ensuring long‑term resilience and compliance with stringent environmental standards.
Construction of the Lorry Park
To support the automated distribution centre, McCoy constructed a 20,000 sqm lorry park designed to accommodate high traffic volumes and heavy goods vehicles. This new external yard tied seamlessly into a high‑level warehouse slab that incorporated eleven dock‑leveller loading bays, enabling efficient vehicle turnaround and integration with the automated systems within the warehouse. The concrete yard slabs alone covered more than 19,500 sqm, reflecting the scale of the logistics operation Nestlé required to future‑proof its supply chain.
A Phased Approach
The project was delivered through a phased handover approach, allowing sections of the facility to become operational while construction continued elsewhere on site. The scheme represented one of the most substantial civil engineering undertakings at the Buxton site in recent years.
McCoy’s ability to manage complex earthworks, deliver high‑specification civil engineering and coordinate seamlessly with the EPC contractor, ensured that Nestlé’s new distribution facility was completed to the highest standards, supporting the company’s long‑term growth and operational efficiency in the region.
The quality of delivery was reflected in the feedback received from the EPC contractor, who praised the leadership and professionalism demonstrated throughout the programme: “McCoy’s Project Manager was an asset to the project and McCoy Contractors, his work and attitude on this project has been extraordinary. The team were a pleasure to work with at all times.” This endorsement captured the strong working relationships and high standards that underpinned the success of the scheme.
“McCoy’s Project Manager was an asset to the project and McCoy Contractors, his work and attitude on this project has been extraordinary. The team were a pleasure to work with at all times.”
Have a project you'd like to discuss? Our team is ready to help.
