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Overcoming complex construction challenges with modular

Managing construction projects is no easy task. Sites can be constrained or hard to access and teams may need to maintain operations while construction is underway or have to work to strict schedules and specific security standards.

Whether it’s in the education, healthcare or defence and justice sector, it’s likely construction teams will be dealing with complex requirements. Historically, this has resulted in large, complicated projects exceeding their target timelines and budgets. However, modular construction offers an innovative solution by providing robust, secure, rapidly deployable buildings for permanent use or short- and long-term rental.

Through our technical professional workforce, careful execution and high-quality solutions, we provide purpose-led offerings for almost any site, sector and application.

Minimising disruption and down time 

Modular construction is used across many critical sectors, as vital operations can continue to function even during complex construction projects where large-scale buildings are installed.

This was demonstrated throughout our project at King’s College Hospital in London, a busy teaching hospital, serving approximately 700,000 people, as throughout the build, we ensured that vital services could remain operational and that patients, staff and the surrounding community weren’t disrupted. For example, the four-storey building’s construction required a 500-tonne crane, so we carefully planned to ensure it didn’t interfere with the air ambulance’s access to the hospital’s helipad.

One of the advantages of modular constriction is that up to 90% of the build takes place offsite, meaning disruption to the live environment and delays due to weather or space restrictions are significantly reduced. Despite the King’s College Hospital installation taking place during winter, meaning shorter days and potential bad weather, our modules were delivered at pace and installed at a rate of eight per day.

Getting the best from even the most constrained sites

So, how does modular construction work? Essentially, we provide transportable buildings that can be delivered quickly no matter how difficult the location. For example, we provided modular solutions to The University of Exeter, when the institution required a new, additional wellbeing facility at the top of a steep hill with difficult access, next to in-use student accommodation.

The new facility had to be built with minimal disruption whilst navigating the complex site safely and our team meticulously planned delivery to get materials to where they were needed. The modules were constructed offsite in our Hull factory, which resulted in up to 50% less time spent on the complex site, compared with traditional building methods. Despite the challenges, the project was completed within the University’s short scheduled timeframe, and we delivered a permanent modular building in just three days.

Performing to the highest security standards

Construction sites and buildings in sectors, such as defence, need to meet high security standards. To ensure these projects can be completed safely, effectively and within the desired timeline, our modular solutions are produced with several key security considerations, including enhanced steel-framed structures. Also, every member of our site team is regularly subjected to thorough security checks and training.

By carrying out construction offsite, both security risks and on-site disruption are minimised. Since the buildings are manufactured in a controlled factory environment, delivery is quicker and fewer security cleared personnel are required on site, and for a shorter duration. For example, at Premier Modular, we developed and installed a Cat C-certified 240 place prison extension to a Young Offenders Institution in the Southeast of England in just 12 weeks while complying with all security requirements. To ensure the integrity of the site and reduce risk, all onsite installation works were surrounded by secure fencing.

Fast construction, delivered on time

Offsite solutions work particularly well when there is a strict delivery schedule.

For example, Debut Services selected Premier Modular to provide three 4-storey accommodation blocks on military bases as part of an expansion project at RAF Coningsby in just 16 weeks.

The modular buildings, constructed from 303 modules in total, comprised 231 bed spaces with one SENCO block. As part of offsite construction, windows were installed, and the bathroom units were fully fitted out whilst still at Premier’s premises. The modules were also taped, filled and decorated, with floorings fitted where possible before delivery to increase the efficiency and ensure the project was completed within the required timeline.

Modular offers a solution to complex site challenges. Offsite construction means that sites can stay operational, projects can be completed more quickly, with less time needed on site, security risks can be limited, and teams can more easily meet specific requirements.

Explore our case studies to find out more or contact one of our experts today.