Case Study: Delivering Coordination at Scale in a Live Construction Environment
Project Snapshot
Project name: Complex multifaceted project for gigafactory
Location: North East
Group: AIS Vanguard
Project duration: November 2023 – Ongoing
Role on project: Specialist logistics, lifting, and installation contractor
Principal Contractor: Wates Construction
The Challenge: Managing Scale, Complexity, and Change Across a Live Construction Site
We were appointed to support the principal contractor at a gigafactory construction project, taking responsibility for the receipt, handling, and installation of over 1,000 individual plant items across a large and highly active construction site. Equipment was delivered from multiple OEMs and required careful coordination between multiple stakeholders on site.
The scope covered a wide range of mechanical and electrical systems, including AHUs, dehumidifiers, CRAC/CRAH units, pump skids, pipework modules, tanks, buffer vessels, chillers, boilers, switchgear, transformers, MCC panels, generators, and associated infrastructure. Each item needed to be received, stored, moved, and installed safely, often in unfinished areas of the building while construction works continued around them.
The scale of the site and the number of contractors operating simultaneously created significant logistical and coordination challenges. Equipment movements had to be carefully planned to maintain safe access routes, avoid clashes, and respond quickly to changing site conditions. This was further complicated by evolving commercial requirements, expanding scope, and the need to comply with construction‑specific regulations rather than production‑based standards.
Our Solution: A Constant On‑Site Presence and Relationship‑Driven Delivery
From the outset, we recognised that success on this project depended on visibility, responsiveness, and trust. We established a permanent on‑site presence, ensuring someone from the AIS team was always available to support coordination and decision‑making. Our team attended daily DABS and coordination meetings, managing permits, access constraints, and work sequencing in real time.
To increase flexibility and remove potential bottlenecks, we installed a dedicated on‑site storage container. This allowed us to receive and hold equipment items safely and respond to last‑minute requests without delay, which avoided the typical two‑week lead times that could otherwise impact programme delivery.
Our approach was strongly relationship‑driven. The on‑site supervisor played a pivotal role, working closely with all external stakeholders on site to find pragmatic solutions to day‑to‑day challenges. By supporting smaller tasks that sat outside the original scope, we helped keep the wider site moving and reinforced our position as a trusted delivery partner rather than a transactional supplier.
Delivering Safety, Compliance, and Control on a Live Construction Site
Operating within an active construction environment required a high level of planning and compliance. Our team produced and managed in excess of 300–400 bespoke Method Statements, Risk Assessments, and Lift Plans, ensuring every activity was carried out safely and in line with site‑specific requirements.
We invested in upskilling plant operatives to meet construction‑site standards, including safety‑critical medical assessments and task‑specific competency requirements. This ensured our team remained fully compliant and site‑ready throughout the project, even as access rules and conditions evolved.
A wide range of specialist equipment was deployed, including MEWPs, forklifts, telehandlers, cranes, PowerAttack systems, Valla cranes, and Versa Lifts, allowing us to adapt to varied access constraints, confined installation zones, and multi‑level lifting operations across the site.
Expertise Behind the Delivery
The delivery was underpinned by experienced Appointed Persons and a site team trained to manage complex lifting and logistics operations within a fast‑moving construction environment. Our in‑house capability allowed us to coordinate crane operations, manual skating, lift‑and‑shift activities, and bespoke temporary works with confidence and consistency.
From a SHEQ perspective, close collaboration with the client was essential. Our SHEQ team attended monthly on‑site meetings and was assessed against a formal scoring system as part of contractor compliance. Maintaining a consistently high score was critical, and the team worked proactively to ensure safety standards, documentation, and site behaviour met expectations at all times – protecting both programme continuity and our operatives’ access to site.
Adding Value Beyond the Scope
As the project progressed, it evolved from a small, discrete work package, originally valued at approximately £100k, into a much more expansive scope, with the contract value growing to around £2.5m.
Our on‑site team went beyond the agreed scope to support the wider project, becoming the go‑to lift and shift team for both planned and ad‑hoc works. This included assisting with site facilities, relocating toilet blocks and gatehouses, and supporting general site operations. Additional labour was introduced to help deliver these tasks, strengthening relationships and contributing to the smooth running of the site.