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Vandyke Upper School
Project Background
Three storey modular teaching block boasts new science labs and general classrooms relocating 6th form study areas, associated external works and two separate refurbishment areas offering more general teaching space and expands the school’s kitchen and dining area.
The Project Manager, James Wood, went on to win Construction Manager of the Year and showcased the project at the awards ceremony.
The Challenge
A site-specific risk assessment should be in place prior to commencing work accounting for the local environment in which the work is undertaken. This highlighted the area beneath the cycle shelter is heavily populated with services feeding the school including LV, HV and Gas. Upon completing several trial holes in accordance with the services plan it was discovered the services were laid shallow in the ground with some having less than 500mm cover.
The Solution
As a result of the incoming services feeding a live school, lowering the services was not a feasible option due to an extended shutdown requirement whilst the works were ongoing. Therefore, a propriety protection board was proposed as a solution to protect the services. The cable protection was specified to be 230mm wide concrete tiles with marker tape to be installed above as a standard requirement. In order to install the protection board, the services needed to be fully exposed and the safest and most efficient method of ground clearance was Vacuum Excavation.
The Results
A site-specific risk assessment was in place prior to commencing work accounting for the local environment in which the work is undertaken.
Vacuum excavation avoided using mechanical means to dig near live services as well as significantly reducing the risk of service strike. It also meant there was no need to disrupt existing services feeding a live school thus the school was able to remain operational throughout the entire process avoiding any disruption.
Working with Eco Modular, the project team utilised off-site manufacturing to minimise disruption, create cost and time efficiencies and enhance the building’s sustainability performance. This created a high Pre-Manufactured Value (PMV) which meant the design could be strictly coordinated and managed with regular inspections, including stringent quality checks, via weekly factory visits. The project also had a high percentage of PMV MEP installation including containment, first fix, plant room design and structured cabling architecture.
The high percentage of PMV on the building produced a better-quality product with less rework and remaining onsite activities were predictable, plannable and labour loading was simpler.
When Covid struck part-way through, it seemed the project may be in trouble but it was delivered on time and to budget in time for the school’s new academic year..
4
Apprentices
60%
SME Spend
£457,373k
Added Value
9/10
Client Satisfaction
Client Testimonials
Contractor Performance | Commitments
Safe
Zero RIDDORs
CCS Score 44/45
Any site specific initiatives
Aftercare
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
Any site specific process/initiatives
Fair
100% payment within 30 days terms
Legacy
A celebratory capsule burying ceremony marked the completion milestone for the students, teachers and project team who worked steadily throughout the peak of the COVID-19 pandemic to ensure the project was safely delivered on time
18 SMEs, 19 beneficiaries, 4 jobs created and 112 trainee weeks
350 students Engaged, £600 donations to charity and 61 volunteer hours
Sustainability
82% of the building by volume was constructed using offsite manufacturing providing a programme saving of 16 weeks over traditional methods
Water tightness was achieved within 2 weeks of modules being delivered speeding up the construction programme
97% waste diverted from landfill
100% timber responsibly sourced
Okehampton Primary School
Okehampton Primary School
Okehampton, Devon
Project Details
Client
Devon County Council
Project Manager
NPS Group
Architect
NPS Group
Contractor
Morgan Sindall
Value
£4.76m
Contract Period
56 weeks
Procurement Type
Framework competitive
Form of Contract
NEC 3 Short Contract
Apprentices
5
Project Summary
Brand new 450 place primary school and associated nursery on a sloping site, within a new housing development on the outskirts of Devon. Construction generally comprised of load-bearing insulation panels for walls, with steelwork bracing to form a two-storey classroom block with ancillary accommodation and double-storey height hall. External works involved hard and soft play areas, MUGA pitch, sports field with two football pitches, landscaping, drainage works and road access.
Key Challenges
Deliveries during adverse weather conditions
Updated the strategy of coordinating deliveries upon arrival to eliminate any difficulties.
School vacation of temporary classrooms no later than 1/4/2018
Robust programming and logistics ensured the school was available for students to start at the agreed date after Easter.
Project Takeaways
Our Success
- Constant communication with the client and sub-contractors with updates on project activities, proactively controlled delays and cost differences.
- Continuous communications with key stakeholders including the client, whole project team, end-user, diocese of Exeter and Devon County Council formed excellent working relationships with the whole team providing a smooth project process.
KPI’s & Statistics
| Contract | Gateway 2 Planning | Gateway 3 Contract Agreement | Variation |
|---|---|---|---|
| Cost | £4,354,992 | £4,375,899 | 0.5% |
| Time | 34.1 weeks | 34.0 weeks | -0.4% |
Bristol Operations Centre
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Project Background
Following the successful completion of Phase 1, Phase 2 refurbishment of Bristol City Council’s headquarters at Temple Street, Bristol including the creation of a new Operations Centre on one floor which provides the central hub for all CCTV cameras in the city. The room also acts as the control centre for major incidents and thus has a higher level of security than the rest of the building.
The Challenge
Provision of high security to one floor and fit out to the rest of the building whilst remaining a live operational building.
The Solution
Specialist and security systems included the installation of a video wall system which feature images from CCTV cameras that operators can play numerous images on enabling them to split the screen or zoom in.
The refurbishment also included CAT 6 data wiring, installation of a new generator, UPS and air conditioning. The new switch panel was installed over 3 weekends as the building remained occupied.
Fit out to the first floor for the Department of Work and Pensions were phased to keep staff entrances live throughout with minimal disruption. Deliveries were planned carefully. Any drilling was not undertaken after 8.30am
The Results
Building handed over on time and within budget whilst remaining operational throughout the works.
4
Apprentices
92.3%
SME Spend
8/10
Client Satisfaction
Client Testimonials
Contractor Performance | Commitments
Fair
100% payment within 30 days terms
Sustainability
100% timber responsibly sourced
Safe
Zero RIDDORs
Legacy
23 No of SMEs
22 Beneficiaries
2 Work experience placements and 16 jobs created
3 curriculum support activities
Aftercare
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
Tufnell Park Primary School
Tufnell Park Primary School
Islington, London
Project Details
Client
London Borough of Islington
Project Manager
Baily Garner
Architect
Haverstock
Contractor
Morgan Sindall
Value
£14.2 million
Contract Period
81 weeks
Procurement Type
Design & Build
Form of Contract
JCT 2011 D&B
Size
3,252 sqm
Project Summary
A new 3FE modular primary school and associated landscaping with new MUGA (Multi-Use Games Area) to replace an existing 1.5FE school. The pupils from the existing school were housed in temporary classrooms while the old school was demolished to make way for the new school. Demolition took place in two phases with one building remaining operational throughout the build and was demolished once the school had decanted into the new building.
The new school is a modular construction by Eco Modular.
“Our project team is extremely experienced and adept at delivering high-quality education projects, often working in logistically challenging urban environments across London, and on live sites. We will bring this knowledge to bear on this development, doing our utmost to minimise disruption, engage both school users and the local community and manage the project to a high standard to ensure the journey to completion is a positive one for all stakeholders.”
Key Challenges
Four metre difference in site levels from pavement level to where the school building is located
A substantial cut and fill was carried out on the site to level it out and a retaining wall was constructed on three sides.
Challenging access and limited space
The site was landlocked by neighbouring properties on three sides and the site was very tight, making access to it very challenging. In the planning stages, permission for the retaining wall of a listed building was sought, but it wasn’t communicated properly how much working space was needed, which resulted in very limited space on each side of the building.
The modular build was proposed by Morgan Sindall as a solution to the tight site and limited access. Eco modular, who provided the building, also carried out the fit-out meaning there was only one contractor to manage for the whole of the building.
There was very little storage on the tight site, so “just in time” deliveries were scheduled to avoid having to store materials on site. All materials had to be craned in or hand-balled over a bridge and entered the building on the first floor.
Live School environment
Working in a live school environment with school children in very close proximity to the site and having to maintain services to the remaining school building.
A road closure was put in place for five weeks whilst the modular building was being delivered and craned into place. During this time, access still needed to be maintained for a special needs school opposite the site, so the road was only closed between the entrance and exit to the school.
The site team worked with the school to get the site set up initially. A good relationship with the school and local community was maintained throughout the course of the project, with regular site visits by the school’s headteacher and office manager as well as letter drops to neighbours.
Site of Interest for Nature Conservation with a number of Tree Preservation Orders
The site team worked with the school to get the site set up initially. A good relationship with the school and local community was maintained throughout the course of the project, with regular site visits by the school’s headteacher and office manager as well as letter drops to neighbours.
Royal Veterinary College: Hobday Building
Royal Veterinary College – Hobday Building
Camden, London
Project Details
Client:
Royal Veterinary College
Project Manager:
Royal Veterinary College
Architect:
Rivington Street Studios
Contractor:
Morgan Sindall
Value:
£7.5 million
Contract Period:
49 weeks
Procurement Type:
Design & Build
Form of Contract:
JCT 2016
Project Brief
The extensive internal and external remodelling and refurbishment of the Hobday Building at the Royal Veterinary College campus in Camden, London. This major refurbishment upgraded and modernised the college’s teaching and communal facilities, which dated back to the 1930’s, to meet current and future demand for student places and to provide a modern state-of-the-art facility to rival international colleges.
Working in a fully functioning college, the remodelling works included a new dining hall, student break out spaces, new laboratories, staff rooms and offices, new WC’s, the entire replacement of an old goods lift and the installation of a new disabled access lift.
Key Challenges
Working on a tight, occupied site
The major challenge of the project was carrying out significant demolition works, strip out of existing facilities, adding new structures and making structural alterations to the existing building with no reduction in occupancy.
We would usually expect this level of works to take place in a vacated building which we had full possession of, with all utilities switched off and temporary services in place, and no concerns about deliveries or movement of people. Carrying out these works in a fully functioning live college of 600 students and 75 staff required meticulous planning, collaboration and communication from both client and site teams.
The programme was developed in phases to allow the college to remain fully operational throughout, including a fully functioning summer school.
Working with animals and accommodating the client
Demolition and major structural alterations were carried out in a fully operational college which, in addition to the staff and students, housed several animals on site including two horses and two cows!
The only outside space was a thoroughfare used for all construction traffic and footfall, access to the site office and the college itself. An agreed process was in place – overseen by our logistics manager – to ensure all animals were safe and not stressed by the works, and that the site staff were safe, when the animals were moved.
From 08:00 to 08:30 and from 16:30 to 17:00 every day, they site team stood down works, cleared and cleaned the area so the animals could pass through safely with no hoist in use, no deliveries planned, no forklifts and no noisy works.
Managing logistics in a very constrained, live site
External space was extremely restricted with only one entrance shared with the college. Just-in-time deliveries were scheduled by our logistics manager, for both the construction site and the college – and across a busy cycle lane – and were all managed by our permanent gateman. Once inside the site, our telehandler unloaded materials which would either be transported by hand to the workforce or enter the building via the hoist at the back of the building.
All materials in and waste out had to pass through a space no larger than a double door. This included plasterboard, steel, timber and bricks.
Keeping to programme while managing asbestos removal
The RVC’s asbestos register didn’t accurately represent the extent of the asbestos throughout the building and a demolition survey was carried out that identified a significant amount more.
The site team managed £300,000 worth of asbestos removal, which was not in the original package of works, without impacting on the programme. This was achieved through communication and collaboration with the client to compile a programme that allowed access to remove asbestos and seal off areas in phases, whilst maintaining access, escape routes and safe working environments for all students and staff.
This was achieved in nine phases, working at night to remove the asbestos, moving it out of the building first thing in the morning and sealing the area during the day before releasing it back to the college once it had been given the all-clear.
Where work had to be carried out on classrooms, disruption was minimised by shutting down the area on a Thursday night and carrying out the equivalent of seven shifts across the weekend so the classroom could be opened up again on Monday morning.
Refurbishment of specialist laboratories
The college’s laboratories were stripped out and refurbished using specialist contractors to design, fabricate and install the laboratory furniture, install reverse osmosis key and medical gas services.
We created new and refurbished fume cupboards and worked with the design team on a brief from users on where to install power, using antibacterial wall trunking.
Specific antibacterial floor and ceiling finishes were sourced to maintain cleanliness and antistatic. The programme was built with specialists and subcontractors to lay flooring after all other works have been carried out to ensure they were 100% sealed and the finish protected.
Contact: Ray Mcauley
Email: ray.mcauley@morgansindall.com
City College, STEM Building
City College, STEM Building
Plymouth, Devon
Project Details
Client
City College
Architect
ADG
Structural/ Civil Engineer
WSP
M&E Engineer:
Hydrock
Contractor
Kier Construction
Value
£9m
Contract Period
March 2016 – July 2017
Form of Contract
JCT 2001 Design & Build
Apprentices
3 Apprentices
Placements
9 weeks work placements
Project Summary
The design and construction of a new Science, Technology, Engineering and Mathematics (STEM) building, along with remodelling and refurbishment of the existing adjacent hall to create a performing arts faculty with associated external works. The project consisted of a 5 storey concrete frame new build with steel frame and atrium.
Specialist design requirements included acoustic work on the ground floor for the music rooms and recording studios.
The design changed to incorporate £1m of value engineering. In the basement the performing arts changing was withdrawn, a handrail around the building for ease of maintenance and the column at the front was changed from square to a v.
Difficulties overcome included the lead designers relying heavily on our design managers and was a big project for the lead architect who struggled to keep up with the pace of the programme
The client was very happy with the result of the design, in particular the cladding and overhang. The result was lots of space for the budget and the internal spaces were well received.
Kier took a lead role in the design management of the project in order to keep to the programme.
Community Engagement
Career Development
- During the project there were 3 management apprentices in Structural engineering from Plymouth University. The project supported the Step In and Step Up programme to encourage career changes into construction and also facilitated a 2 week placement in site management for a former Royal Marine.
Key Challenges
Live Campus
Live campus environment required weekly co-ordination meetings with the Clients estates team to ensure deliveries were kept a a minimum during peak campus activity.
Demolition
Demolition of existing building on a live campus. To minimise risk, demolition of the existing building was carried out during school holidays. A robust risk method statement was developed which included dampening dust and protective screens over large glazing.
Project Takeaways
Our Success
- Value management was carried out on the existing building roof through overlaying a roofing system rather than replacing the entire roof. It was identified that there was no requirement for new plant, resulting in a quick solution and avoided lost time.
- Examples of value engineering on the project included reducing the depths of overhangs on the eaves. This created a more definite frame, reducing construction of the floor overhang to be supported from the ground. The style of the balustrades was also changed and the atrium changed from glass roof to 3 large roof lights.
- Best practice of innovation is demonstrated in the curved handrails on the roof; they have been designed so that they are not visible from the ground but still ensure safety when carrying out maintenance on the roof.
- Innovation was demonstrated through the concrete wash out used.
Our Learnings
- To ensure the safety and security of the site, there was a full hoarding around the perimeter which was inspected daily, skips were covered and delivery restrictions at peak times.
- Off-site storage was established so that materials only arrived on site when required.
Value Added
- The key cost drivers were the financial targets and due to a client funding agreement there was a turnover date that had to be met.
- The programme was driven by the College who needed the building to be in use for September 2017.
East Anton Primary School
Andover, Hampshire
The Challenge
To minimise energy consumption and maximise occupant comfort, our team focused on the careful design of the building form and selection of materials. In particular, the layout of the proposed building features south facing classrooms with north facing clerestory glazing. This arrangement offers good opportunities for providing generous natural daylight with natural cross ventilation and effective shading from excessive solar gain.
The Solution
Willmott Dixon’s team of education experts have created a new 420 place primary school in Andover. The school provides places for students aged from 4-11 years old and is likely to expand in the future with elements already in place to accommodate this.
This arrangement offers good opportunities for providing generous natural daylight with natural cross ventilation and effective shading from excessive solar gain. The school is highly sustainable with photovoltaics on the roof which provide 10% of the building’s energy use.
The Results
The Primary school provided 420 places for students aged from 4-11 years old and is likely to expand in the future with elements already in place to accommodate this. Set within the East Anton Major Development Area (MDA) the school is being built alongside 2,850 new homes with developer Taylor Wimpey.
1
Apprentices
91.25%
SME Spend
20.5%
Added Value
10
Client Satisfaction
Client Testimonials
Contractor Performance | Commitments
Fair
100% of payments were made promptly and within 30 days
Sustainability
98% diverted from landfill
Legacy
Created 9 new jobs through the project
Career guidance events
Provided over 186 weeks of training onsite
Safe
Zero harm
Aftercare
SCF handover and aftercare process carried out
Police Investigation Centre, Portsmouth
The Challenge
Building on the success of the Basingstoke PIC [link], the challenge was set by OPCC to develop an identical facility for the Portsmouth site but deliver it quicker and cheaper. Whilst this excluded site abnormals, the focus was on seeking efficiencies in the design by adopting an off-site manufacture / kit of parts approach.
The Solution
Using the BIM model to carefully interrogate the design the focus was on which elements of the design could be premanufactured and delivered to site, taking the benefits of quicker delivery. The building cores were one focus area, rather than a concrete cast in-situ approach, these were revised to a twin-wall solution. The MEP installation was another focus area, with plant modules being manufactured off-site alongside horizontal services modules for distribution across each floor.
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The Results
The programme benefits delivered through the adoption of premanufacture achieved an approximate 3 week saving and consequential cost saving. The wider benefits included quality checked products, reduced site labour and associated health and safety impacts such as periods spent working at height together with a reduced waste.
6
Apprentices
£19.3m
SME Spend
£1.4m
Added Value
10
Client Satisfaction
Client Testimonials
Contractor Performance | Commitments
Fair
Client and sub-contractor payments made within 28 days of certification date.
Sustainability
The installation of PV’s supported the buildings achievement of BREEAM.
Safe
Zero RIDDORs
Legacy
Programme of engagement with UTC Portsmouth to support curriculum activities.
Aftercare
Mace supported the early occupation and operation of the building through maintaining our MEP and Construction Managers on site for the first 2 months to ensure smooth operation and running of the building.
Barnet Waste Transfer
London
Project Team
Architects: Capita
Electrical: Capita
MEP: Capita
Project Background
The project was a design and build development of Oakleigh Road South Vehicle Depot to create a Barnet Council vehicle depot and a base for their fleet of 46 household recyclable waste collection vehicles.
The Challenge
There were several challenges faced throughout this project. There was restricted access on a long and narrow site which caused difficulties when trying to overcome other challenges such as dealing with the below ground water, removing underground drainage structures and the buried hazardous waste.
The Solution
To overcome the narrow site, the Willmott Dixon team worked in a ‘patchwork’ fashion, sectioning off the works and moving operations around to keep the access road fully open throughout the build.
Willmott Dixon found existing sewers and then got permission from Thames Water to use them instead for the below ground water. They found a solution using a land drain pump to drain the ground water which was causing surface water.
The Results
Now built, the depot will allow Barnet Council to operate its vehicle maintenance and recycling collection fleet from single coordinated site, ensuring the most efficient service for residents across the borough. The construction also consisted of a tractor barn and car parking, together with associated ancillary facilities, a recycling waste transfer building and bulking facility, a two storey office and welfare building.
2
Apprentices
88%
SME Spend
£1.2m
Added Value
9/10
Client Satisfaction
Contractor Performance | Commitments
Sustainability
Early contractor engagement realised that by raising finished floor levels by introducing an engineered ground geotextile design produced a saving of c£720k, helping significantly reduce excavated materials resulting in programme saving £110k.
Added surveys resulting in reduced risk on hazardous waste, saving £205k
Fair
Regular payments and payment periods did not exceed 30 days
Safe
Zero RIDDORs
Legacy
2 starter apprentices who went on to gain full time graduate employment
Aftercare
SCF handover and aftercare promised carried out
Middlemoor Criminal Justice Centre
Exeter
The Challenge
The main challenges relating to this project were optimising the design to meet budget and making sure the design of the custody cells were Ministry of Justice compliant.
The Solution
Early appointment formed an ‘integrated team’ newly formed with common agreed objectives were able to de-risk prior to any works commencing on site. This aided and protected final account predictability which contributed to completing on time and on budget.
Built to Ministry of Justice standards using the Yellow book design guide providing first-class accommodation for solicitors and partners has been incorporated in the design, including interview rooms and medical suites. The custody centre will use modern technology to monitor the health of vulnerable detainees and offers a virtual courts system. The linked-hub buildings provide modern office and meeting space for all operational police functions.
The Results
Completed on time and on budget. Willmott Dixon worked collaboratively with their Works Partner of the Year, Stephenson Group, to reduce the in-situ concrete frame programme by 12 weeks Exeter Police Station met all the requirements for Time, Cost and Quality achievements: defect free, on budget and handed over on time after being completed two weeks early. The project used 67% Mandated Suppliers and 82% Cat A suppliers, proving that building closer relationships builds trust and improves quality and service BREEAM Excellent certification accredited to design stage and is in UK’s top 10% sustainable buildings.
6
Apprentices and ex-defenders
78%
SME Spend
£6.3m
Added Value
10
Client Satisfaction
Client Testimonials
Contractor Performance | Commitments
Fair
99% of regular payments and payment periods did not exceed 30 days
Sustainability
The facility uses 22% less energy than a traditional building of the same size, generates 68kwh of electricity a year from solar panels and carbon generated from its construction has been offset
Safe
Zero RIDDORs
Legacy
Held 100 school children visits
1,600 students engaged at career events and workshops
2 ex-military personnel joined the construction industry
Aftercare
Zero defects at handover & aftercare
