PROJECT DESCRIPTION:
Designed by Cornish Architects and constructed by Harmonix Construction, PFE Express’ new headquarters in Witham marks a major milestone in the company’s expansion. Built on a greenfield site adjacent to Waterside Business Park, the state-of-the-art facility reflects PFE Express’ continued growth, ambition, and commitment to operational excellence.
The development includes dedicated airfreight bays, bulk storage areas, and two mezzanine levels supporting reworks, repackaging, and relabelling activities. Very-Narrow-Aisle (VNA) racking maximises pallet holdings, trebling previous capacity, whilst expanded staff facilities, modern training rooms, and collaborative office spaces enhance working environments and promote efficiency.
At more than double the size of their previous site, the new building reinforces PFE Express’ long-standing roots in Essex and provides a sustainable, future-ready base for continued growth.
Create worked collaboratively within a multidisciplinary design team comprising Powell Tolner & Associates Ltd, The Millbridge Group, and Fire Dynamics. Our contribution spanned MEP Building Services, Acoustics, Sustainability (including BREEAM AP) consultancy to support design, compliance, and certification objectives – culminating with the confirmation of BREEAM ‘Very Good’ rating in December 2025.
WHAT WE DID:
PLANNING STAGE
- Energy Statement
Outlined strategies to minimise operational energy demand and reduce primary energy consumption, reduce CO2 emissions and enhance energy performance of the building.
- Sustainability Statement
Supported planning compliance by demonstrating alignment with local and national sustainability policies.
- BREEAM Pre-Assessment
Early-stage evaluation of the project’s sustainability objectives to determine its potential BREEAM rating and inform future design strategy.
- Lift Specification
Produced lift performance and design criteria documentation ensuring accessibility, efficiency, and compliance with current standards.
- Noise Impact Assessment
Supported planning compliance by demonstrating how the new development affects surrounding noise levels.
- Building Life Cycle Assessment (LCA)
Undertook an LCA of superstructure and options appraisal for materials.
- Low and Zero Carbon (LZC) Feasibility Study
Produced an LZC Feasibility Study. As part of this, we quantified energy savings and associated CO₂e emissions across all feasible low and zero carbon technologies for the scheme, including air source heat pumps (ASHP) and solar PV.
DESIGN STAGE
- MEP Design and Specification
Delivered full Mechanical and Electrical Services Specifications covering heating, ventilation, air conditioning, lighting, and power distribution systems to achieve energy-efficient performance and user comfort.
- Glazing Specification
Defined acoustic and thermal performance requirements for the building envelope to optimise comfort, energy performance, and noise control.
- BREEAM Assessment for Interim Design
Undertook the BREEAM design stage assessment and submitted the scheme to BRE, resulting in the issue of an Interim Design Stage certificate at Very Good level.
- BREEAM Hea01 Daylight Assessment
Modelled internal space to maximise natural daylight and reducing energy costs and environmental impact by reducing the need for artificial light. The study ensured that the occupied area meet good practice daylight factors and illuminance level.
- Hea05 Pre-Acoustic Assessment
Predicted noise environments to inform early design refinements.
- BREEAM AP Services (RIBA Stage 3 and 4)
Guided the design team to ensure sustainable performance goals were achieved.
- Technical Notes & Contract Prelim Sign-off
Provided technical clarifications and verified design documentation prior to construction.
- Design Stage Pol 05 Plant Noise Assessment
Demonstrated that potential noise impacts from external plant and any required mitigation were recommended during the design phase.
- Sound Insulation Testing
Conducted testing for noise break out.
- Internal Acoustic Assessment
Predicted, controlled, and enhanced sound within the building during its design phase to ensure it was fit for purpose and complied with regulatory requirements.
CONSTRUCTION STAGE
- Plant Noise Assessment
Evaluated potential noise impacts from external plant to meet planning and acoustic standards.
- Operational Noise Assessment
Ensured building systems met acoustic comfort and compliance requirements.
- Noise, Vibration and Dust Monitoring
Undertook on-site monitoring to ensure compliance with environmental limits, working closely with the contractor to investigate and resolve any exceedances identified.
- U-Value Calculations
Determined how effectively the building resists heat loss by measuring heat transfer and finding the thermal resistance of each layer, ultimately providing calculations for the roof, walls, and floors.
- BREEAM AP Services (RIBA Stage 5 and 6)
Ensured compliance was achieved throughout RIBA Stage 5 and 6. We visited site and advised on risk and opportunities, monitoring progress, carried out compliance audits, and help the project team to generate appropriate documentation for certification and sign-off.
POST-CONSTRUCTION STAGE
- Hea05 Sound Insulation Testing
Verified acoustic performance and compliance with Building Regulations.
- As-Built EPCs and lodgement
Confirmed the new building met UK Building Regulations (Part L) by providing validation reports to BRE, leading to final Building Control sign-off and registration.
- BREEAM Post Construction Stage (PCS) Assessment
Final BREEAM evaluation and reporting to confirm as-built performance and secure formal certification.
KEY ACHIEVEMENTS / BENEFITS
- Planning Approval Secured
Planning approval obtained from Braintree District Council in 2023.
- Achieve strong energy efficiency and sustainability credentials
Supported the design of a high-performing facility meeting BREEAM and local energy policy standards through efficient building systems and sustainable design principles.
CLIENT FEEDBACK
“Harmonix Construction thoroughly enjoyed working with the Create team, who demonstrated real versatility throughout this comprehensive build. The team provided excellent support during the M&E design stages alongside Alan DeMerquis, and were equally strong across the BREEAM and BRUKL/EPC scopes, with Sunanda Swain proving incredibly helpful throughout.
At key planning stages, where significant reports and technical investigations were required, Ben Dixon was exceptionally proactive and supportive, ensuring high-risk planning conditions were successfully discharged. This was achieved through detailed reporting, robust investigations, and well-considered design and operational improvement recommendations.”
Darren McQuibban, Project Director at Harmonix Construction