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OFFSITE CONSTRUCTION


the new theatres have been running six days per week at maximum capacity.


Modular vs. traditional build The Trust considered and explored modular and traditional build structures before making its decision. It was looking for a solution that reduced disruption to what is a very busy site, and which would allow ease of management. ‘Going modular’ was the standout solution, because of the speed of the build, with a programme time of just seven months from order to handover. If the Trust had opted for a traditional two-storey build, it is likely now that it would only be halfway through the programme.


The new, state-of-the-art theatres were built off site, dismantled into 26 deliverable units, and then craned into the site with minimum disruption over a six-day period. The Trust and ModuleCo worked with Interclass, which was responsible for the enabling works on the site – including the foundations, links to the existing theatre and ward blocks, and the incoming services.


The site was complex, dating back to the late 1800s. There were service ducts and an underground stream and culverts which had not been mapped, and which we were aware of. The plant room was underground. Over 1,000 cubic metres of earth had to be dug out and removed from the site so that the level could be reduced by two metres. This was programmed and carefully controlled in such a way that disruption was minimised, and most staff were unaware that it was happening.


Work started on site in May 2019. After the enabling works were complete, 26 modules were craned in after manufacture at a dedicated construction facility in Mitcheldean, Gloucestershire.


Inside a modular building


When you are inside a modular healthcare building it looks and feels no different to any other conventionally built facility you will find in a hospital. The finishes benefit from being completed in a controlled factory environment, and cannot be distinguished from traditional finishes. ModuleCo Healthcare worked closely with the staff who were going to be working in the facility, to ensure that they had the opportunity to influence the design and finishes.


For example, the nursing team had the chance to influence the colour scheme, the layout, the bathroom locations, and the best position for the four-bed wards. Traditionally, a four-bed ward would only have one bathroom, and it was not uncommon for three people to have to wait for it to come free. The nurses requested an extra shower room and a WC in that space, so it was designed in. Additional WCs were included in the


A reception area inside the new theatre building.


communal corridor areas, so that now patients do not have to wait if they need to use the facilities. The layout of the six- bedded recovery bay was changed, and the colour and finishings chosen to reflect a calm ambience.


Snagging


As you would expect with a project of this scale, minor snags are unavoidable. For example, when the units were craned in, some internal walls needed recovering due to minor cranage stresses. Thanks to the strong partnership approach between the various parties, any issues were worked through and resolved quickly. We had regular site meetings – three informal Friday meetings on site, and one minuted formal meeting to monitor progress. A unique advantage of modular construction is that the building can be


snagged in the factory, enabling a great many of the identified issues to be resolved before the modules are delivered to site.


Financing the project


The Trust agreed a managed services contract with ModuleCo Healthcare for an initial long-term commitment of 10 years. The rental is inclusive of the facility, enabling works, and equipment, for both the theatres and ward levels. It means that no capital investment was required from the Trust for the new modular facility, allowing for it to be paid for through the additional revenue generated. One of the key objectives of the project was to build future resilience. The new facility has helped the Trust to address the financial and other risks posed by ageing theatres that could fail at any time.


Staff open the new modular facility at the Royal Orthopaedic Hospital in Birmingham. April 2020 Health Estate Journal 57


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