The Castle School

  • Client

    South Gloucestershire Council 

  • Contractor

  • Value

    £11m 

  • Completion Date

    June 2024 

The Challenge

The Castle School project in Thornbury required a significant expansion to support its growing Sixth Form cohort, requiring a new threestorey 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 exambased restrictions: Noisy or disruptive works could not clash with GCSE and ALevel 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 schoolday traffic movements: With hundreds of daily dropoffs and pickups, deliveries needed strict control to avoid congestion and maintain site safety 

The Solution

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. No deliveries were allowed between:
  • 8:00–8:45am (dropoff) 
  • 3:30–4:00pm (pickup) 
  • Deliveries were also precisely coordinated through a JustinTime management system, ensuring materials arrived only when needed, between 9:30am and 2:30pm, again, reducing onsite congestion and eliminating unnecessary vehicle idling. 
  • Noise was controlled with clear environmental thresholds established:  
  • 75dB – warning limit 
  • 85dB – “dead stop” limit requiring immediate cessation of works 
  • Decibel monitors were installed at multiple sensitive locations, including Park Road, Regents Close, Alexandra Way Residential Care Home, and a nearby new housing estate. 
  • Lastly, a robust traffic management strategy was implemented.

The Results

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 highquality 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.  

10

Number of apprentices

69.4%

SME Spend

£53,700

Added Value

9/10

Client Satisfaction

Contractor Performance | Commitments

Legacy

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

Sustainability

100% waste diverted from landfill 

43T of CO2e saved  

100% timber responsibly sourced 

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 

Safe

Zero RIDDORs 

CCS Score 45/45 

100% Safe 

Fair

100% payment within 30 days terms

Client Testimonials

The thought of a huge construction project was daunting, I’ve never had any experience in that area – It could have been really chaotic! But to be honest, most of the time I wouldn’t have even known that the work was going on. I got regular updates; I was allowed on site to see progress and all of that reassured me. It never felt like we were unsafe, because of the relationship between Morgan Sindall and the school.