Caledonian was shortlisted in the Infrastructure Project of the Year category.
The Offsite Awards recognised how Caledonian’s futuristic offsite modules have revolutionised worker accommodation at Hinkley and opened up a world of new opportunities for other large infrastructure as well as residential housing projects.
When Caledonian was awarded Hinkley Point C (HPC) it was the largest ever modular contract in the UK, on the largest infrastructure project in Europe. Caledonian was appointed by EDF Energy to design and build the modules, whilst Laing O’Rourke installed them on site.
Highlights of the modular project delivery by Caledonian include completing the 51 week schedule – effectively creating a new town of 1,496 en-suite bed spaces – 4 weeks ahead of schedule.
The modular accommodation supplied by Caledonian is equivalent to a three-star hotel and were delivered to HPC near Bridgwater in Somerset 96% complete. With only 4% of the build on site, each 34 bedroom block was completed in just 6 weeks from delivery.
Hinkley Point C will require around 5,600 workers at peak construction and will take 10 years to build and supply 7% of the UK’s electricity. Some of the accommodation units will then be de-mounted and reused in the wider Bridgwater community, another innovative aspect of the Caledonian modular solution recognised in the Offsite Awards.
The project was a true reflection of Caledonian’s ‘collaborative’ approach from the outset, which helped deliver the project ahead of time, in budget and aligned with all legislative and H&S requirements.
Paul Lang, Chief Executive Officer at Caledonian Modular, said: “Housing providers should take note of what we have achieved at Hinkley – effectively creating a modular new town that houses 1,496 workers in just 51 weeks. That makes it a practical blueprint for solving the UK’s housing crisis. If the government’s rhetoric on building more houses via offsite translates into action – Hinkley is the shape of things to come.”
Caledonian’s innovative modular solution shows what is possible with modern volumetric solutions – it enables the incorporation of extensive facilities and amenities, such as large-span catering areas, sports and leisure spaces, lift shafts and atriums. These helped increase its attractiveness to higher skilled workers at HPC – a major benefit for EDF Energy.
This ability of Caledonian to consistently deliver the Hinkley modules to the strict schedule required by main contractor Laing O’Rourke was possible because of the company’s use of BIM, design for manufacture and assembly (DMFA) and lean manufacturing techniques.
The exterior design of the modules set Caledonian apart on this project, too. At three storeys, the buildings are sympathetically executed to complement the surroundings, using natural timber and stone-effect cement cladding, creating an attractive exterior facade.
Caledonian’s strength as an organisation was also recognised in the awards – the company was able to manage the £55m HPC contract, whilst servicing existing construction projects, and ensure business sustainability when work was completed by securing other large contracts. This included top spot on the £300 million ESFA Batch C Modular Framework and, working with Bowmer & Kirkland, a £25m contract to manufacture bedroom accommodation modules as part of a £54m development of First Way Campus in Wembley.