Quarry Works, Surrey

Two high-specification industrial units built from scratch in a Surrey chalk quarry — retained as long-term portfolio assets.

Set within a former chalk quarry on an 18-acre site in the Surrey countryside, Quarry Works represents one of YayYay's most complex ground-up commercial construction projects. The scheme involved the development of two industrial units of substantial scale, complete with 20kN-rated solid concrete mezzanine floors, 6-metre eaves, a privately installed water harvesting and drainage system, and a security-gated hardstanding yard extending to approximately one acre. Both units remain in the YayYay investment portfolio.

The site began as a working forestry holding. YayYay cleared, levelled, and prepared the quarry floor before undertaking all enabling, civil, structural, and building works as principal contractor — managing everything from initial vegetation clearance and chalk extraction through to the installation of self-sufficient infrastructure, structural steel erection, and final fit-out. The quarry setting presented significant ground engineering challenges, with chalk subgrade requiring careful assessment and engineered foundations throughout.

Built to Office Standard — For Maximum Flexibility

A key strategic decision was to build both units to office-standard building regulations rather than purely industrial specification. This was a deliberate investment in long-term flexibility: it means either unit can be converted to office, studio, or alternative commercial use in future without requiring structural upgrade works or change-of-use complications. The insulation specification, air tightness, and services provision all reflect this ambition — the buildings perform significantly above minimum industrial standards.

The sheet-clad steel frame construction with insulated composite cladding panels delivers strong thermal performance, whilst 6-metre eaves give exceptional internal volume and operational flexibility for a wide range of end uses including storage, workshop, light manufacturing, or technology.

20kN Mezzanine Floors

Each unit includes a full-width solid concrete mezzanine floor rated to 20 kilonewtons per square metre — a heavy-duty structural specification that accommodates plant, machinery, racking, or ancillary offices at height without restriction. The mezzanines are not lightweight steel decks: they are reinforced concrete slabs on structural steelwork, engineered to the same load capacity as a commercial office floor. This was another deliberate decision to maximise future use flexibility and asset value.

Self-Sufficient Infrastructure

The remote quarry location necessitated the installation of a fully private infrastructure system. A rainwater harvesting system was designed and installed to serve the site's water requirements, supplemented by a private foul drainage system — making the development operationally self-sufficient and independent of mains connections. This was a technically complex undertaking, requiring careful sizing of tanks, filtration, and distribution systems to meet the anticipated demands of both units.

The yard area — extending to approximately one acre of hardstanding — was fully engineered with correct falls, drainage, and a robust load-bearing sub-base capable of supporting heavy goods vehicles. A security-gated entrance with perimeter boundary treatment completes the site's commercial security provision.

Scope of Works

Acting as principal contractor across all phases: site clearance and vegetation removal; chalk quarry floor levelling and preparation; engineered foundations on chalk subgrade; structural steel portal frame design and erection; insulated composite cladding and roof panel installation; reinforced concrete mezzanine floors (20kN rated) with structural steelwork; rainwater harvesting system; private foul drainage; 6-metre eaves height throughout; roller shutter doors and personnel access; internal lighting, power, and services; one-acre hardstanding yard with engineered drainage; security-gated perimeter entrance.