Defence College of Technical Training, Lyneham

Number of modules - 1196

Specified to an equivalent standard of a three-star hotel, each of the new individual bedroom units manufactured and installed by Caledonian comprises wardrobe, desk, lighting and power fittings, an ensuite shower room and curtains. Each individual module was approximately 90% fitted out before leaving the Newark-based factory.

The Defence College of Technical Training project was particularly time sensitive and a modular solution for the accommodation was always a key consideration. The client, the DIO, has for more than a decade championed the use of modern off-site methods of construction and modular building was an obvious fit.

Roger Frost, Balfour Beatty Project Director said; “One of the major benefits of using modular systems in construction projects is that high levels of safety, productivity and quality can be reached for our clients”.

A preliminary 3D model was created by Architects, Scott Brownrigg to help visualise the project. 3D modelling based upon BIM principles was utilised to create structural details for factory manufacture and to co-ordinate with M & E design. 3D modelling enabled the design team to produce larger volumes of drawings for steelwork fabrication in order to increase factory production volumes and to enhance accuracy of manufacture. Lean manufacturing methodologies enabled the manufacture of 10 modules per day to meet the required programme.

Caledonian leveraged past experience, in-house knowledge of the technical standards and performance criteria required by the client, production capability (as the United Kingdom’s largest supplier of offsite solutions), the ability to meet a very tight programme (and still remain cost competitive) to drive a successful selection process.
The diversity of size and scale of the buildings (initially 11 buildings – however, a 12th building was added post contract award), providing 1145 bedspaces covering five different variants of Joint Service Publication (JSP) Scales, required a careful, diligent and professional approach by all involved in delivering the completed project in 11 months.

An opportunity for inherent efficiency existed due to the sheer scope and scale of the scheme. Efficient design lead to efficient production. In addition, as the 12 buildings are three or four storeys in height, commonality of parts enabled replication across the scheme. In general terms during the modular manufacturing process, when utilising a repeat working method, by the 100th unit, 30% efficiency savings are achieved.

Caledonian buildings meet the DIO’s DREAM (Defence Related Environmental Assessment Methodology) Excellent rating.

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