Former Amazon Warehouse | Econ Group

Project Overview

Econ Group were appointed as Principal Contractor to deliver the internal enabling works at a former Amazon warehouse facility in Hemel Hempstead. The building was being prepared for refurbishment. Our remit included all internal strip-out, dismantling of major plant and infrastructure, and the safe clearance of materials and waste.

Scope of works included:

• Strip-out of all non-structural internal components
• Removal of M&E installations, fire suppression systems, racking and conveyors
• Safe dismantling of multiple large air handling units (AHUs)
• Removal of hazardous materials including localised asbestos
• Management of all waste streams including separation and disposal
• Full dismantling of a large mezzanine structure occupying the central warehouse span

We provided all site welfare, permits and supervision, with Econ staff managing daily briefings, service isolations and H&S compliance.

Focus: Mezzanine Dismantling

The mezzanine structure was the most complex part of the project. It occupied the central footprint of the warehouse and had integrated connections with racking, electrical services, overhead plant and fire protection systems. The structure itself was steel framed, multi-tiered and constructed using a combination of welded and bolted fixings.

Conditions on Site:

• The mezzanine supported large mechanical units, cable trays and ducting
• Flooring was composite and mechanically fixed
• There was limited overhead clearance in several zones
• Adjacent services and retained infrastructure needed to remain intact

Methodology:

We approached the mezzanine dismantling in phased stages. This allowed us to maintain plant access, control material flow and avoid clashes with other ongoing works.

• The central span was opened up first, running north to south. This created a working corridor for machines and allowed clear segregation of active areas.
• A 20-tonne excavator with shear attachment was used to dismantle the upper steel framework, working bay by bay.
• A 13-tonne excavator with selector grab followed the shear, lifting and processing material into skip-ready sections.
• Perimeter zones and tighter areas were completed using MEWPs. Operatives carried out manual cutting using reciprocating saws and hand tools.
• AHUs were dismantled in sections. Small elements were manually removed, and larger sections were cut down, chained and lifted out using a 21-tonne excavator with a slinger.
• Support brackets, bolts and anchor points were hand-cut after load was secured. This allowed controlled removal from roof areas without structural damage.

Safety and Control:

• Exclusion zones and drop zones were strictly enforced, with signage and supervision in place at all times.
• Toolbox talks were held daily, focused on active zones, service status and changes to methodology.
• Permit systems were used for hot works, excavation and confined access.
• All waste was separated at source and removed via 40-yard skips in regular rotation.
• Asbestos works were completed by trained operatives, with localised enclosures, safe removal and full documentation.

Programme Delivery

Despite the scale and volume of works, the project was delivered ahead of programme and within the agreed cost parameters. The site was handed back clean, compliant and ready for refurbishment. There were no safety incidents or near misses recorded.

Key Takeaways

• Mezzanine structures should never be underestimated. They often involve multiple construction types and connections to other systems.
• Phased dismantling with a clear access and movement strategy allowed us to maintain continuity and avoid standstills.
• Flexibility between mechanical and manual methods made a significant difference. Excavators handled the bulk of steelwork, while hand tools gave us control in tight areas and during deconstruction near live assets.
• Early creation of working corridors gave plant and operatives uninterrupted access across the programme.
• Exclusion and drop zone discipline ensured the safety of all on site while works progressed simultaneously across different areas.

This project reflects our ability to deliver complex internal enabling works under live principal contractor conditions. If you are planning a logistics, warehouse or industrial redevelopment and need a clean, compliant start point, we would be happy to discuss our approach.