case study

Warehouse Fit-out



Project Description

Stewarts Commercial Contractors had the esteemed privilege of collaborating with DHL, a global logistics giant, to fit out a cutting-edge parcel distribution centre in Exeter. This project was an amalgamation of innovation, precision, and the relentless drive to deliver excellence. From the construction of the PUD (Parcel Unloading and Distribution) fingers to the development of a full-fledged employee amenity zone, every element was meticulously planned and executed.


The principal goal of this ambitious project was twofold. Firstly, to elevate an existing warehouse into an advanced parcel distribution facility, capable of handling the complex logistical needs of today’s fast-paced commerce. Secondly, to ensure that the centre was not just a high-performance machine but also a conducive environment for its workforce. This involved the integration of PUD fingers for efficient parcel management, state-of-the-art Stertil roller shutter doors for secure loading, and a range of employee amenities that focused on comfort and well-being.






18 wks






September 2022

PUD Fingers: Engineering Efficiency

Structural Integrity: Steel Portal Frame

The PUD (Pickup-Delivery) fingers served as the lifelines of the distribution centre. Crafted from a robust steel portal frame, these structures were designed for long-term durability and resistance to various environmental factors. The portal frame offers an ideal balance between tensile strength and flexibility, making it a suitable choice for housing sophisticated conveyor systems.

Cladding: Not Just a Cover

The exterior was not an afterthought but an integral part of the design. Composite micro rib cladding panels were chosen for their lightweight yet sturdy nature, which aids in both insulation and structural integrity. These cladding panels also add an aesthetic element, ensuring that the PUD fingers look as good as they function.

Stertil Roller Shutter Doors: Security Meets Efficiency

The selection of Stertil roller shutter doors was a strategic choice. With 30 doors fitted to each PUD finger, they offer fast and secure loading and unloading capabilities. Built to withstand the rigours of industrial use, these doors are both durable and easy to operate, providing an ideal blend of security and operational efficiency.

evitec logo

Sustainability Installations: Leading the Charge Towards a Greener Future

Solar PV System: Harnessing the Sun’s Power

As part of our commitment to sustainability, a state-of-the-art Solar Photovoltaic (PV) system was installed on the roof of the distribution centre. This system not only lowers the centre’s carbon footprint but also makes a significant contribution towards renewable energy production, aligning with DHL’s long-term sustainability goals.

EV Chargers by Evitec: Electrifying the Fleet

Stewarts Commercial Contractors collaborated with its sister company, Evitec, to bring a robust Electric Vehicle (EV) charging infrastructure to the site. Evitec, a specialist in EV charging solutions, was awarded a contract to install 20 EV charging bays, demonstrating DHL’s unwavering commitment to sustainable logistics.

On-Site Planning and Installation

The project kicked off with a thorough on-site assessment, followed by meticulous planning and installation phases. Evitec’s experienced team ensured that the construction and commissioning were completed to the highest quality and safety standards within a 5-week period.

The Benefits of EV Charging

The installation of these EV charging bays serves multiple purposes:

  • Reduced Operational Costs: Switching to electric vehicles brings down operating costs, offering savings on fuel and maintenance.
  • Lower Carbon Footprint: The move aligns with DHL’s sustainability goals by significantly reducing carbon emissions.
  • Enhanced Brand Image: This initiative bolsters DHL’s reputation as a responsible and forward-thinking organisation.
  • Improved Employee Experience: For DHL employees who drive electric vehicles, these charging bays offer a convenient and fast charging solution.
  • Future-proofing Operations: As the world moves increasingly towards electric mobility, this installation positions DHL to stay ahead of the curve.

Evitec and Stewarts are proud to contribute to DHL’s vision for a greener, more sustainable future.

“Stewarts has set a new benchmark with the Exeter parcel distribution centre, integrating cutting-edge PUD fingers and a sustainable Solar PV system. Their commitment to efficiency and sustainability has not only transformed our operations but also underscored our commitment to a greener future.”

DHL Exeter – Ray Tullet


Employee Amenities: Where Comfort Meets Productivity

Bathrooms: A Focus on Hygiene and Comfort

Our commitment to employee well-being extended to the construction of state-of-the-art bathroom facilities. Modern fixtures were chosen, and attention was paid to details like water-saving mechanisms and hygiene factors, ensuring a comfortable experience for staff.

Canteen: More than Just a Dining Space

A fully-equipped canteen was designed as a multifunctional space where employees could not only dine but also engage in casual conversations, contributing to a cohesive work environment. With a variety of seating options and a modern kitchen setup, it serves as an ideal space for relaxation and rejuvenation.

Office Space: Designed for Productivity

We recognised that a well-designed office space can significantly boost productivity. Therefore, an ergonomic layout was implemented, featuring adjustable furniture and state-of-the-art technological provisions. The aim was to create an environment where tasks could be executed efficiently, without compromising on comfort.

Recreational Space: The Balance Factor

Lastly, a dedicated recreational area was designed to offer employees a space to unwind and engage in leisure activities. From comfortable seating to entertainment options, this space was curated to promote a balanced work-life atmosphere, contributing to overall employee satisfaction.

Conclusion: Setting a New Industry Standard

The culmination of this 18-week, £2.6 million project stands as a testament to Stewarts Commercial Contractors’ dedication to delivering excellence. We are immensely proud to have partnered with a global leader like DHL and look forward to raising the bar even higher in future projects.