Cardinal Logistics' Stage 1

Cardinal Logistics’ new Drury site is the country’s first fully automated facility with an overall capacity of 115,000 pallets. Stage 1, completed in 2023 has a capacity of managing 12,000 ASRS (Automated Storage and Retrieval System) pallets. Stage 2 will add another 48,000 pallets and the completion of stage 3 will see a further 55,000 pallets delivered from this site for the country’s’ largest privately owned 3PL provider.

Haydn & Rollett invited Conslab for early design engagement to provide advice and design the right floor for the ASRS requirements. The robots and automated retrieval trucks are highly dependent not only on the levelness and flatness of the floor but also the high-quality surface finish. To ensure smooth operation of the automation, FM2 Flatness to EB15620 was required in the warehouses while the surface was mechanically trowelled to a highly burnished finish.

Contracts Manager, Mark Turner from Haydn & Rollett said, “We were fortunate to have the expert assistance of Conslab deliver our slabs on Cardinal Drury Stage 1. The design needed to be unique due to the automation requirements, and the delivery faultless, and Conslab delivered on all fronts. Their team had the Clients interests at heart and no problem couldn't be resolved through hard work and collaboration”.

The design team provided solutions through Dramix “Combi-Slab” option to meet the various design loads for racking, automated pallet cranes and forklifts. This solution incorporates both 400mm & 200mm thick floors with steel fibre and mesh heavy-duty reinforcement to provide a robust solution in the warehouses. The 200mm thick external yard slab was designed for 30-tonne containers stored 2 high moved by Combilift SC-3 Straddle carrier.

This ~45,000m2 project (including warehouses and external yards) was delivered on time over 9 months with completion of Conslab scope in July 2023. “Conslab played a huge part in the success of this project and their contribution was very much appreciated”. Said Mark Turner from Haydn & Rollett.