The Castle School project in Thornbury required a significant expansion to support its growing Sixth Form cohort, requiring a new three‑storey extension for Maths and Science teaching. The project also required a link bridge connecting the new block to the existing secondary school building, ensuring a seamless campus layout.
However, delivering this scheme posed several key challenges largely around disruption to the school; this included:
Working within a live school environment: Works were undertaken while the school remained open, meaning student safety, staff access, and uninterrupted learning had to be protected at all times.
Complex ground conditions: Beneath the preserved tarmac areas lay Type 1 build-up and shallow hard rock, meaning foundation and drainage works required drilling operations that risked generating prolonged noise.
Tight exam‑based restrictions: Noisy or disruptive works could not clash with GCSE and A‑Level exam periods, narrowing the available working windows.
Sensitive neighbouring receptors: Surrounding residential streets—Park Road, Regents Close, Alexandra Way—and a nearby care home required careful environmental management around noise and dust.
Busy school‑day traffic movements: With hundreds of daily drop‑offs and pick‑ups, deliveries needed strict control to avoid congestion and maintain site safety
The project team implemented a comprehensive package of operational controls, programming adjustments, and environmental protections to deliver the new block safely and efficiently.
Disruptive works such as rockbreaking and drilling tasks were scheduled outside exam periods, with the majority delivered during the summer holidays to avoid noise during teaching hours.
The team kept as much of the existing roadway and hardstanding in place which reduced unnecessary ground disturbance, improved site cleanliness, and prevented mud tracking onto public routes
Timed delivery restrictions were introduced to avoid conflict with school traffic.
Through meticulous planning and a proactive approach to environmental and stakeholder management, the project was delivered with:
Minimal disruption to school life, including zero clashes with exams despite significant drilling and groundworks.
Enhanced safety for students, staff, visitors, and construction personnel due to carefully managed vehicle movements and clear site logistics.
Excellent environmental performance, with noise and dust impacts effectively controlled and monitored in real time.
A modern, connected Sixth Form facility offering high quality Maths and Science teaching spaces, improving the school’s capacity and creating a more cohesive campus layout.
A successfully delivered project that demonstrates how thoughtful planning enables significant construction activity within challenging live school environments.
Amid the challenges faced, the project was delivered one week ahead of programme.
100% waste diverted from landfill
43T of CO2e saved
100% timber responsibly sourced
Zero RIDDORs
CCS Score 45/45
Soft landings for handover and Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
100% payment within 30 days terms
87.1% No of SMEs, 15 jobs created, 12 Work Experience (11 – in Education/ 1 – not in education)
546 training weeks on site (Apprenticeships, Traineeships, Technical/Higher Level Qualifications)
£1.3k donations to charity/material donations, 28 volunteer hours, £6.5m social value created
Selecting a frame structure which met HCC’s fabric-first principles and prioritised energy-efficiency through the building envelope.
Unique to other panel systems, the Streif timber frame solution provides fully made cassette panels including external doors and windows already installed and M&E systems pre-measured and cut-out. It was therefore critical to get these details correct from the start, so the timber frame was dispatched on time to meet key site deadlines and ensure the school was ready for the September 2025 term start.
Other challenges include ensuring fire safety compliance for timber frame construction, facilitating site readiness by implementing strategic remediation and sustainable soil management protocols, and selecting a ventilation system which supported the project’s energy and design efficiency requirements.
Aligned with the fabric-first design intent, the Streif panelised timber frame solution was adopted for its myriad benefits over traditional structures including improved U-values, reduced embodied carbon and quicker watertightness; while leveraging experience from previous Streif projects.
Seamless coordination with the supply chain was critical to maintaining the programme. Numerous coordination meetings were executed with MEP, stairs and groundwork specialists, ensuring fully coordinated design, manufactured and delivered on-time. This meticulous planning enabled a seamless ‘soft landings’ approach with FF&E and IT specialists, guaranteeing the school was fully operational for the new term start.
Fire safety was rigorously managed throughout the construction process, with strict adherence to the Safe2Torch policy, MSC’s hot work protocols, and the implementation of thorough fire watch procedures.
Existing soils were stockpiled and tested for suitability. Materials that did not meet the required standards were removed. Where possible, retaining/ reusing soils and materials was prioritised, reducing waste and supporting sustainability while meeting all remediation requirements.
MVHR units were selected instead of ASHP primarily to reduce pressure within ceiling voids.
Championing the ‘fabric first’ design philosophy, the Streif system resulted in exceptional environmental performance with an air test rating of 1.16m3/(h.m2)@50Pa and near-Net Zero status of 205CO2.
The proactive approach ensured timely delivery of the timber frame; subsequently meeting key deadline dates.
The project achieved ‘Perfect Delivery’, meaning it was delivered 100% Safe, on-time, within budget and to a delighted customer.
Successfully implemented and complied with the remediation strategy; while also supporting sustainability aspirations which included 100% waste diverted from landfill.
By using localised smaller MVHR units, ductwork and material usage was minimised, achieving a more efficient design while preserving ceiling space for other services.
12 apprentices, 37 SMEs , 27 beneficiaries, 6 jobs created,
108 trainee weeks and 2,722 students engaged
£9,000 donations to charity
39% social value created
Community Quad – 2,574 hours
100% timber responsibly sourced and waste diverted from landfill
226kg/ 100k carbon footprint (against target of 454kg)
30.6 tonnes CO2e saved in MSC 10 Tonne Carbon Challenge (embodied carbon)
17 tonnes of CO2e saved from emissions (Scopes 1,2 and 3)
Waste reduction with 0.71 tonnes per £100k spend, outperforming the national target of 1.28
Zero RIDDORs
CCS Score 45/45
CCS Bronze Award
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
100% payment within 30 days terms
Ensuring a heat protection strategy due to the function of the building.
The new facility was designed to present fire fighters with the experience of tackling fires in a controlled situation. The facility provides them with an environment where they can study how fire behaves in different conditions and the best practices to respond to the fire. With the facility use in mind, it was important that the facility was designed to withstand serious fire.
Negating challenges faced working within a live blue light environment.
The project took place at the Hampshire & Isle of Wight Fire & Rescue Service HQ, where training took place in close proximity to the site. The site was also shared with Hampshire & Isle of Wight Constabulary, which meant there were a number of parties to be mindful of during the build and it was pivotal we maintained their daily activities.
Managing safety on the project with forward planning and frequent communication.
Numerous challenges were faced during the construction of the live fire building including coordination of the crane, working at height and being in close proximity to the local airport and railway.
The Live Fire Training Facility is one of very few of its kind in operation and presents vital experience to trainees as they tackle controlled fire situations whilst experiencing realistic after-effects and complications under supervision; forming a key part of fire fighters training in Hampshire and the surrounding areas.
15 SMEs (9 local) – 13 beneficiaries – 3 jobs created
Schools engagement: 949 students – 130 trainee weeks
£1.93 LM3 – 92% social value created
16.2 tonnes carbon equivalent saved in Morgan Sindall’s 10 Tonne Carbon Challenge by changing the heat protection tile supplier to a UK supplier, reducing number of and distance of deliveries
98% waste diverted from landfill
7 biodiversity enhancements
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
Zero RIDDORS and a CCS Score of 40/45
100% payment within 30 days terms
Cosham Fire Station is one of three new fire stations constructed by Morgan Sindall Construction for our client, Hampshire and Isle of Wight Fire and Rescue (HIWFRS). Delivered through the Southern Construction Framework (SCF), the new facility contributes to the HIWFRS’s wider initiative to regenerate their fire stations via a £27m investment.
The aspiration for this project was to provide a new and enhanced facility with state-of-the-art equipment, which, would improve the level of training operatives could receive. Part of the overall scope of works required the inclusion of staff welfare facilities, community facilities and a Police Station.
A safer facility was also crucial, with operatives often left covered in toxins which could have potentially long-term detrimental effects to their health. Therefore, the design of the building was carefully considered to ensure it could meet this requirement.
The previous Cosham Fire Station was located on Wayte Street in Cosham. However, with an eye on having a larger facility, the new fire station was relocated onto the land of the former Portsmouth Craft and Manufacturing Industries (PCMI) on Northern Road. However, demolition was required to the PCMI buildings, which was subcontracted to HWM Group. The relocation of the fire station was fundamental as the new facility spreads across two acres of land and is three stories high.
The larger facility meant that it was possible to design and embed a decontamination route into the building. This ensures operatives now follow a decontamination process as they navigate through the building. The decontamination route is colour coded as:
Red – Removal of contaminated clothing
Amber – Shower and clean for removal of smoke on skin etc.
Green – Decontaminated area such as admin wing and appliance bay
The new route mitigates the transfer and inhalation of toxins for the operatives, in turn, providing a safer working environment for the operatives.
Along with providing a safer space for operatives, the facility will act as a training hub for the East region of Cosham. The facility includes a new training tower along with additional training facilities for the workers. The improved facilities will now provide operatives with the best training possible to respond to emergencies in the most effective way possible.
Cosham Fire Station had been designed in such a way, that both the exit and entrance could be adapted; providing trainees a challenge every time they enter the building.
37 No of SMEs – 44 beneficiaries – 10 jobs created – 526 trainee weeks – Schools engagement – 147 students – 100 volunteer hours – £1.70 LM3 – 88% social value created – £3k donated to the Queen Alexandra (QA) Hospital Portsmouth – 16 School engagement events
96% waste diverted from landfill
100% timber responsibly sourced
10T challenge successfully completed – 556T co2e saved
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
Zero RIDDORs and CCS Score 43/45
100% payment within 30 days terms
Winton Academy was a logistically tight and challenging site. This was due to the fact that construction was surrounded on all four sides by live class blocks and with a farm within close proximity.
There was great emphasis placed on the quality of the new facility; however due to the lack of space on site, the team were unable to accommodate a ‘benchmark’ room.
100% waste diverted from landfill
100% timber responsibly sourced
39 No of SMEs – 18 beneficiaries – 7 jobs created – 53 trainee weeks
Schools engagement: 2955 students & 131 hours
£175 donations to charity – £2.32 LM3
78% social value created – 88% local spend
Soft landings with a dedicated Morgan Sindall point of contact
On-line portal for notifying defects with 3 priority categories for response times
Zero RIDDORS – CCS Score 44/45
100% payment within 30 days terms
Operating Within a Live School Environment – Delivering major construction works within an active SEN school presented significant logistical and safety challenges. Maintaining uninterrupted educational activities while managing construction traffic, deliveries, site access, noise, and safety required exceptional planning, clear communication, and robust site controls. Protecting vulnerable learners remained a priority throughout the construction programme.
Design and Programme Complexity – The project scope changed significantly when the hydrotherapy pool was introduced after construction of the teaching block had already begun. This required programme re-sequencing, redesign of construction logistics, and careful integration of a new Design and Build package alongside ongoing works. The team needed to take the hydrotherapy facility from concept design through detailed design, procurement, construction, and commissioning without impacting the completion commitments for the wider project.
Stakeholder Management – The site was surrounded by several key stakeholders, including local residents, a neighbouring fire station, and a football club. Construction activities had the potential to affect access arrangements, traffic movements, and day-to-day operations. Effective engagement and transparent communication were therefore critical to maintaining positive relationships and minimising disruption.
Collaborative Delivery Approach – Morgan Sindall adopted a collaborative and transparent working relationship with Surrey County Council, the design team, school representatives, and specialist stakeholders. Regular workshops, open communication, and decision-making enabled challenges to be addressed early, ensuring project momentum was maintained throughout delivery.
Strategic Site Logistics and Construction Planning – Detailed site logistics planning was implemented to manage the simultaneous construction of both facilities within a constrained operational school environment. Careful coordination of deliveries, contractor movements, and access routes ensured works progressed safely and efficiently while minimising disruption to school activities and neighbouring organisations.
Robust Quality Management – Quality assurance was embedded throughout the project through close supervision by the Morgan Sindall site team, supported by the client’s Clerk of Works. Regular inspections, collaborative reviews, and proactive issue resolution ensured that the specialist educational and therapeutic requirements of the facilities were delivered to the highest standards.
Proactive Community and Environmental Initiatives – Regular sessions were held with the school and external stakeholders, helping to build trust and address concerns. Environmentally, the project achieved 100% diversion of waste from landfill and 100% responsibly sourced timber. The team also retained and reused stripped topsoil on site, eliminating the need for imported materials and reducing project carbon emissions by 12.7 tonnes of CO₂.
The project was delivered successfully, with the new teaching block handed over and operational in accordance with the original contract completion date. The hydrotherapy pool was also completed and brought into use in line with the agreed programme, despite being introduced after construction had commenced. Performance outcomes demonstrated the success of the collaborative approach with a score 10/10.
The project also delivered significant social value, including engagement with 29 SMEs, the creation of opportunities for 6 apprentices and new entrants, 57 locally employed workers, and 168 weeks of training delivered. Educational outreach activities engaged over 380 students, while a pioneering work experience programme provided valuable insight into careers in construction for local pupils. The scheme generated more than £2.3 million of added social value, reinforcing its long-term community impact.
Most importantly, the completed facilities now provide high-quality learning and therapeutic environments that support the needs of pupils and staff, leaving a legacy for Philip Southcote School and the wider community.
29 SME’s used on the project
6 new entrants, a total of 57 locally employed employees, equivalent to 5.79FTE
168 training weeks completed during project delivery
Schools engagement: 9 students completed a work experience placement, MSC attended 4 CIAG events interacting with 380 students.
£650 donations to charity, in addition the site team contributed 5 (1 per MSC staff member) hampers towards our Christmas Hamper drive, which we donated to local Runnymede Foodbank
£1.79 per £1 – 24.95% social value created
We collaborated with both Philip Southcote School and Fordway AP to launch a pilot work experience programme, giving 16 students the opportunity to explore a range of disciplines across the construction industry. Throughout the week, students engaged in site tours, met professionals from various roles, and took part in open, honest conversations about careers in the field. The programme concluded with student teams presenting their ideas on how to improve sustainability in the build. Feedback from both students and teachers highlighted the positive impact and inspiration the experience delivered.
100% waste diverted from landfill
100% timber responsibly sourced
Storage and reuse of stripped top soil at the start of the project, did not require any imported top soil to reinstate the field area, reducing the carbon of the project by 12.7 tonnes.
Good communication between MSC/ Client team/ End user regards post completion works.
Continuation of delivery into aftercare – Chris Horsley is dedicated Morgan Sindall point of contact for aftercare supported by Steve Sear
On-line portal for notifying any defects with 3 priority categories for response times
Zero RIDDORS
CCS Score 44/45
100% payment within 30 days terms
The design was carried out in two volumes – developing the design for the school and for future extension. The project had a BIM Level 2 requirement with a verification point cloud survey to be carried out prior to handing over the asset information model.
The biggest challenge was the Building Control review of the high performance fast-track SIPS construction and associated structural elements (supporting steelwork and precast concrete first floor and stairs).
Morgan Sindall took the project from RIBA Stage 2 and developed the design to Stage 5. A BIM model was produced which incorporated the architectural, structural, civil, MEPH and specialist sprinkler designs. The FF&E and catering subcontractor models were developed alter and incorporated in the Project Information Model.
The school was built using Structural Insulated Panels (SIPs) structural frame with a series of panels manufactured off-site and assembled on-site. To make best use of the clash detection process, the SIPSs subcontractor Innovare began work alongside the design consultants at Stage 3. The MEPH subcontractor also began work early during the design period allowing access zones around the plan equipment to be added to the BIM Execution Plan as a modelling item. Once the SIPs frame was installed, it was laser scanned. The scan output could then be used to compare the built asset against the digital model.
The use of a Project Information Manager was invaluable to the design team meeting COBie requirements. This resulted in the last validation reporting showing Stage 4 data was on target and met the Information Exchange requirements. The design team continued to develop the model with a final update carried out after the point cloud information was issued to form an accurate Asset Information Model.
The off-site manufacture approach created a bespoke solution which provide cost efficiencies through a standardisation of the process and increases sustainability through a fabric-first approach. The SIPs were manufactured under factory controlled conditions resulting in a system that was extremely quick to install, strong, energy-efficient and cost and time effective.
29 No of SMEs – 22 beneficiaries – 5 jobs created – 155 trainee weeks
Schools engagement: 30 students – 86% social value created
£300 donations to charity – 30 volunteer hours
97% waste diverted from landfill
100% timber responsibly sourced
Order placed with Community Wood Recycling resulting in 14.3 tonnes collected with a saving of £492.06 and the majority being high-grade reuse.
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
Zero RIDDORS & CCS Score 43/45
100% payment within 30 days terms
Built to be net-zero in operation, Silverwood also represents the future of sustainable education estates. The school reaches net zero carbon through a combination of renewable energy and low-carbon systems and materials.
Over 1,000 solar panels generate more than 400 MWh annually—enough to power the entire facility, with surplus energy exported to the local grid. Three biomass boilers provide sustainable heating. In a pioneering community energy initiative, the solar panels are owned and operated by Wiltshire Wildlife Community Energy, generating approximately £5,000 annually to support environmental education at the school. Material choices were also at the heart of Silverwood’s highly sustainable build with embodied carbon reduced through use of a Cross Laminated Timber (CLT) frame.
As a result of the precise construction methods and materials, the building achieves an airtightness score of 1.843/hr/m2 - that’s highly energy efficient compared to the average modern building, which is around 53/hr/m2. The school also achieves an EPC score of –13. The negative number indicates that the building generates more energy than it consumes annually. Sustainability by design drove every element of the project plan. Silverwood achieved remarkable results in construction waste management: 98.8% of all construction waste was diverted from landfill. This positive environmental outcome was achieved through a comprehensive Material Management Plan.
The project diverted 25,000 m³ of excavated material for complete on-site reuse, while 1,096 pallets were collected by Pallet Loop for reuse instead of disposal. Community Wood Recycling Social Enterprise collected 256 tonnes of timber from the site, and 10 pallets of spare bricks were donated to St Edmunds Society for apprentice training.
Silverwood students also gained valuable learning opportunities by constructing bird boxes made with reused waste timber from the construction site. All hard and soft plastics were segregated and recycled. Insulation offcuts were collected and sent offsite for reuse.
By reusing 100% of excavated material on-site rather than disposing to landfill, the project saved an estimated £715,000 in avoided disposal costs. This calculation factors in landfill gate fees, landfill tax, and haulage costs minus onsite management expenses, demonstrating that sustainable construction makes both environmental and economic sense.
6718 students engaged with and 115 trainee weeks
4% Biodiversity net gain 25,000m3 excavated materials reused on site
Zero RIDDORS
100% payment within 30 days terms
Soft landings for handover
Willmott Dixon’s specialist residential team worked with OX Place to build Bridges Cross, a new community providing a mix of 36 homes for local people in Speedwell Street.
Made available for council tenants, shared owners and homeowners, with almost three-quarters affordable. It comprises of a single block of four to six storeys, made up of 18 one-bed flats, 17 two-bed flats and one three-bed flat.
Bridges Cross was designed by Levitt Bernstein Architects and supported with £1.38m from the Oxfordshire Housing and Growth Deal. It sits on the site of a 13th century Dominican Order (Blackfriars) friary that was demolished after the dissolution of the monasteries by Henry VIII in 1538
To reduce running costs for people living in the homes, Bridges Cross incorporates a “fabric first” approach where the homes are designed with enhanced insulation and air tightness standards. This prevents heat leakage when cold but also supports passive cooling when warm. It is supplemented by rooftop solar PV panels which generate up to 60 per cent of the development’s overall energy use.
Further features include a green roof that improves air quality, aids natural cooling, absorbs rainwater, and encourages biodiversity
The minimal carbon footprint is further supported by being a car-free development, except for two parking spaces equipped with EV chargers for flats adapted to people with mobility needs. Also, every flat is provided with two bike parking spaces
All properties within the development will operate at 40% below current government carbon reduction targets
100% payment within 30 days terms
Zero RIDDORS
Soft landings for handover
207 :trainee weeks
The project faced a multitude of challenges, including a live site adjacent to the construction area, imposing constraints on logistics and site management.
The task of developing a school tailored to cater to the needs of children with severe learning difficulties, particularly those with SEN/ASD, added layers of complexity to the project.
The tight timeline further enhanced the situation, demanding innovative solutions to adhere to the tight programme.
Using Modern Methods of Construction (MMC) proved instrumental in achieving both time and cost savings, enabling the project to stay within the confines of the client’s budget while meeting the ambitious schedule.
Through a comprehensive lessons learned process, Morgan Sindall Construction established a continuous improvement cycle, capturing insights and best practices from each project stage.
Collaborating with Streif, consultants, and internal design managers, the team refined design coordination processes, emphasizing the importance of early-stage design freeze to streamline offsite manufacturing and to make sure the project was within programme and budget.
The implementation of these refined processes and strategies led to smoother project progression and minimized potential delays.
By prioritising effective site segregation and communication strategies, Morgan Sindall Construction successfully mitigated disruptions to school operations during construction, ensuring a conducive learning environment for students.
This commitment to continuous improvement not only enhanced project efficiency but also reinforced the organization’s reputation for delivering high-quality, impactful construction projects.
Due to using MCC this project achieved significant carbon savings of over 1220 tonnes and reduced transport miles by a staggering 132,000.
The expansion not only met but exceeded expectations, with a 10/10 customer satisfaction rating.
5 workless job starts
97 trainee weeks
Schools engagement: 2 careers fairs.
7 work placement week
Soft landings for handover
Dedicated Morgan Sindall point of contact
On-line portal for notifying any defects with 3 priority categories for response times
100% timber responsibly sourced
1220 Tonnes of Carbon saved
Zero RIDDORS and a CCS Score of 45/45
100% payment within 30 days terms