Warehouse & Distribution

Oakleaf Materials Recovery Facility (MRF)

Stanwell Moor

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Client: Stadler UK

Project: Fit-out coordination for large-scale waste facility near Heathrow.

Cost: £18M

Services: Project Management

RIBA Project Stages: 5-6

Delivery of a state-of-the-art recycling facility processing 150,000 tonnes annually.

David Hall Business Development Director "It was fascinating to see first-hand how our waste is segregated into its various waste classifications for potential reuse, recycling, and recovery. Projects like this will pave the way in the UK’s bid to become more sustainable and achieve net-zero carbon emissions."

The opportunity

Located near Heathrow, the Oakleaf MRF was designed to process 150,000 tonnes of commercial and industrial waste each year, enabling separation of metals, plastics, wood, paper and card. Any remaining waste is processed to produce Solid Recovered Fuel (SRF), providing an alternative to fossil fuels. The 5,000 m² building includes a reception area, processing equipment, storage bays, and an extensive fire detection and suppression system. TPI were employed by Stadler UK Ltd to assist with the process machinery and plant fit-out, as well as helping to identify and resolve any design clashes with the base build contractor.

The challenge

TPI provided a site-based role to support Stadler in their function as Principal Contractor under CDM regulations. A key challenge was managing the significant overlap between Stadler’s fit-out works and the base build works due to programme pressures. Careful coordination of these overlapping scopes, close communication between all parties, and timely resolution of design and sequencing issues were critical in maintaining progress, ensuring safety, and avoiding disruption to the overall delivery.

The outcome

TPI’s input was highly valued by stakeholders. Once the original duties for Stadler UK Ltd were completed, Oakleaf Limited re-engaged TPI to coordinate the outstanding completion and commissioning works required to bring the facility fully into operation. The building remains in use today as a functioning waste processing facility.

"During the Oakleaf Project I had the pleasure to have the Total Project Integration team managing a multitude of interfaces between the process installation and the civils installation. Next to very efficient management of daily engineering tasks and spotting potential clashes in advance I found they were always enthusiastic and engaged, positive and patient in achieving project goals. Their attitude was inspirational to other members of the project and their presence on site has played a significant factor in making the project successful overall."
Dr Benjamin EuleDirector, Stadler UK Limited