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Case Studies

AMC Engineering Ltd - Aberdeen

AMC Engineering Ltd - Aberdeen

  • Client - AMC Engineering Ltd
  • Project size - 532m²
  • Completion - 11 weeks
  • Office and Welfare Facilities
  • Ground floor - 3 No. Offices, 2 No. Meeting rooms, Reception/Waiting Area with Entrance Lobby, Server & Electrics room and WC's
  • First floor - 13 No. Meeting rooms with linking corridor
  • Pitched roof with integrated downlights

AMC Engineering required an Office block and Welfare facility for their Aberdeen branch which Module-AR were awarded the contract to design, manufacture & install.

On the ground floor of the building there are 3 No. Offices of varying sizes, 2 No. Meeting rooms, a large Reception/Waiting Area with entrance Lobby, a Server & Electrics room, fully-fitted Kitchen, Cleaners' Store, male & female WC's and Corridor linking each room.

The first floor of the Module-AR Limited structure consists solely of 13 No. equal sized Meetings rooms, a Corridor linking each room and the internal Stairwell. The Offices, Reception, Meeting rooms and Corridors are all fitted with Primavera carpet tiles whereas the Kitchen and WC's feature hard-wearing, easy to clean Polyflor Polysafe Vinyl flooring. Heat & Cool air conditioning was installed throughout the building along with window blinds and suspended ceilings.

Externally, the AMC Engineering building features Plastisol (plastic coated steel) cladding, plinths and fascia. A pitched roof with integrated downlights within the soffits and external door canopies were also installed to give the Module-AR Limited structure the look of a traditional build.

Only 2 days were required for Module-AR Limited to install the building with a total project completion time of 11 weeks - this is up to 50% faster than if the project was completed traditionally.

AMC Engineering Ltd - Aberdeen
Woodhill Primary School - Woolwich

Woodhill Primary School - Woolwich

  • Client - Royal Borough of Greenwich Council
  • Project size - 904m²
  • 9 classroom block
  • Traditional Brickwork cladding
  • Completion - 20 weeks

Module-AR Limited secured the contract to design, manufacture and install a brand new 3 storey modular building for Woodhill Primary School to accommodate Reception, Year 1 and Year 2 pupils. The Building Bulletin Compliant BB101 & BB93 structure was manufactured utilising our AR4000 steel framed structure which has a lifespan of 50 years and is capable of being stacked up to three stories high - as this project is.

Each floor houses a different school year, with reception on the ground floor, allowing direct access to external play areas, Year 1 on the first floor and Year 2 on the second floor. They each feature 3 No. 56m² classrooms with hat & coat pegs, dedicated wet areas, storage facilities with sliding doors and Smartshade blinds for use with the interactive whiteboards. A large lobby and corridor area joins the ground floor Classrooms with adjacent staff & pupil WC's, Plant room, Cleaners' room, 2 No. Staircases and a 3 storey DDA compliant platform lift. The first floor layout features the same 3 No. Classrooms, pupil WC's and Staff Offices layout. The top floor of the building features glazed domed roof lights for improved natural lighting to the corridor area, 3 No. classrooms, 2 No. Small Group rooms and the addition of 2 manual roof access hatches. These are operated with retractable ladders allowing safe access onto the roof. The building incorporates an 1,110mm high parapet wall to the full perimeter of the roof to obscure roof-mounted plant including photovoltaics. The parapet also allows safe access around the roof area for future maintenance without the need of a Roof Mansafe System.

The Secured by Design modular building is clad in brickwork which gives it the look of a traditionally constructed building. It was also designed in this way to compliment the existing 3 storey Grade II Listed School building. A lightning protection system was installed to comply with the criteria and recommendations of the BS EN 62305 Part 1 & 3 Protection. Brise Soleil panels have been fitted to the first and second floor west and south facing elevations with a cantilevered canopy to match the windows complete with fritted glass to the ground floor classrooms. On the roof, which includes a 30 year BBA Certification roof covering with roof parapet, are mounted photovoltaics to improve sustainability. These eco-friendly features assisted Module-AR to achieve a BREEAM Excellent rating for Woodhill Primary School. BREEAM is the world's foremost environmental assessment method & rating system for buildings and sets the standard for best practice in sustainable building design, construction and operation. Achieving BREEAM Excellent status certifies that Woodhill Primary School is in the top 10% of UK new non-domestic buildings with regards to sustainability.

Due to the size of the modular building project, and restricted site access, a 200t crane was required to lift the modules into position. This resulted in the adjacent road being closed for 4 days. The road closure was pre-planned in conjunction with the Royal Borough of Greenwich Highways Department to minimise disruption to the school & local community and the delivery & installation took place during the school's half term.

To deliver 36 No. modules in just 4 days in a busy residential area is an impressive feat which the School and Local Authority were extremely happy with. Not only was this efficient, but the entire project took Module-AR just 20 weeks to manufacture, and install and complete on site.

Words From The Client

Kate Jarrett, Headteacher at Woodhill Primary School, stated that Module-AR Limited's communication and performance of the Site Manager were excellent. The advice, technical expertise, skills & performance of the pre-contract team, health & safety, completing the works to programme, quality and performance as a whole were very good. Kate also commented: "Module-AR worked efficiently and communicated well with the school. They really wanted to understand what our needs were, and did their utmost to meet them."

We have also completed other modular building projects for Royal Borough of Greenwich Council, Greenwich Peninsula School & Kidbrooke Skills Centre for further information, please feel free to contact us

Woodhill Primary School - Woolwich
Parish CoE Primary School - Bromley

Parish CoE Primary School - Bromley

  • Client - London Borough of Bromley
  • Project size - 1,009m²
  • Modules - 26
  • Factory build - 7 weeks
  • Installation - 4 days
  • Completion - 30 weeks

Parish Church of England Primary School is a 2 Form Entry Modular Building Primary School for children between the age of 4-11 set in 5 acres of parkland on the outskirts of Bromley town centre. The mansion building housing much of the school dates back to 1770's and the school itself, which has previously occupied other sites, is probably the oldest educational establishment in the borough - tracing its history back to 1717. The London Borough of Bromley were seeking to expand Parish CoE Primary School, in order to address the bulge of children coming in to the education stream, from a 2 Form of Entry to a 3 Form of Entry.

Module-AR Limited were granted this modular building project to demolish all existing 'mobile' accommodation that the school was using (including the removal and destruction of asbestos-filled buildings) to make way for the new purpose-built accommodation. Once the demolition of the existing structures had taken place, Module-AR designed, manufactured and installed a 26 module single-storey building covering a footprint of over 1,200m².

The structure consisted of 12 No. Classrooms with storage space, a Corridor with cloak areas, 1 Group room, sufficient toilet accommodation for children and adults (staff and visitors), an Entrance Foyer and Plant room. External ground works (including the relocation of a time capsule) were also included in the full Turnkey modular solution.

Child-height interactive whiteboards, suspended ceilings, over-provision of power outlets for the increasing volume of electronic equipment, wireless IT connectivity throughout the building, wet areas within classrooms, roof lights for increased natural lighting and Breathing Buildings R Series Systems in each classroom for improved sustainability were installed to make the building perfect for Primary School use.

Externally the building features aluminium windows & doors, timber cladding procured through FSC® certified sources and a large external covered canopy to encourage outdoor learning. The canopy was also fitted with integrated planting to further improve the aesthetics of this already fantastic looking building.

The full project including the removal of the existing old building and the design, manufacture & installation of the new structure took just 30 weeks which allowed Parish CoE Primary School to occupy the modular building solution as soon as possible.

Words From The Client

Mr Hilary Richardson, Headteacher at Parish CoE Primary School, commented: "Module-AR have provided Parish CoE Primary School, Bromley, with a fine new 12 classroom block to complete its expansion to 3 Forms of entry and replace some dilapidated building stock.

From the start of the project, the company provided a first-class professional service. The work has been completed on time, to a high professional standard and within costs. The most important aspect from an educational point of view is that everything has been achieved without any disruption to the day-to-day educational running of the school.

I would certainly recommend Module-AR to anyone involved in the consideration of a new-build school project."

Alongside this fantastic reference from the School's Headteacher, the Senior Project Manager at the London Borough of Bromley Mr Simon Goodburn also commented: "The School, following sanction by the Secretary of State, agreed to expand their existing accommodation to provide an additional 1 Form of Entry, from 2 to 3 classes per year group.

The Local Authority in joint collaboration with the School and design team, comprising Keegans Ltd and cost consultants Mott MacDonald, undertook a competitive tendering exercise following comprehensive design and consultation work including planning consent.

Following Executive Member Approval, the Authority appointed the successful tendered Module-AR Ltd to progress the provision of a detached modular building to include the 12 No. new classrooms, toilet accommodation and group rooms in line with the designs and planning consents already obtained.

Under a JCT 2011 Design and Build Contract, Module-AR Ltd appointed their own in-house designers, contracts manager and construction delivery team with the module units being manufactured in their own facility near Hull, East Yorkshire. The modular building project was to be delivered in time for the start of the new academic year with demolition of 3 mobile blocks and 1 steel framed 2 storey block. The removal of hazardous asbestos from the 2 storey block as well as providing 8 No. temporary classrooms for the decanted children for a term was included within the package of works. The logistics involved in coordinating this work via a restricted access with listed brick piers either side was to be a challenge, and an occupied site during School term time presented additional hazards that any experienced contractor would find problematic.

I am pleased to write however, that the School took possession of a fully functional new modular building at the start of the new term. The on-site communication with the School was exemplary and the 'behind-the-scenes' management of materials, plant, goods and operatives was particularly well done with very little disruption to the School throughout the full 30 week contract.

The School have ended up with a fantastic new facility which offers a bright, open and spacious accommodation, aesthetically sitting comfortably against the historic mansion house. Module-AR Ltd as a main contractor provided a no-fuss approach to this build, providing regular updates to the School and Authority Client Team. They dealt with issues promptly and have successfully delivered the contract on time and within budget. A good news story all round and we sincerely thank everyone who took part in the process."

Why not have a look at similar projects that we have completed or contact us for further information.

Parish CoE Primary School - Bromley
Rail & Transport
Network Rail - Stockport

Network Rail - Stockport

  • Client - Network Rail
  • Project size - 2,186m²
  • Completion - 14 weeks
  • 2 Storey Office & Welfare Facility
  • Part Cedar & Part Kingspan External Cladding

Module-AR Limited were granted the project to design a 2,186m², 2 storey, 64 No. module Office and Welfare facility for Network Rail. The structure was designed & built to accommodate 132 Office staff with Welfare facilities for 240 staff at their Stockport branch.

This purchase building was finished externally with Plastisol (plastic coated steel) which was bonded to 9mm WBP exterior grade plywood. The plywood panel was fitted to a timber frame to form a stressed skin construction. The part Cedar and part Kingspan cladding chosen by Network Rail creates a modern & aesthetically pleasing structure.

The external windows of the Network Rail Stockport building are thermally broken PC Aluminium frames incorporating laminated & toughened glass, fitted with Trickle Vents to provide background ventilation. All windows can be opened and cleaned from the inside of the building, reducing the risk of falls from ladders as associated with external cleaning methods. The external doors of the building are manufactured from double skinned 1.2mm Zintec steel with interlocking seams and reinforced interlocking channels & tubes to prevent twisting.

The interior of the building was designed to meet Network Rail corporate DNA. This generates a creative and productive environment that is a pleasure to work in. On the ground floor of the fully Heat & Cool air conditioned building is a Briefing room, Meeting room, Archive room, with an enhanced 5kN/m² floor loading, 4 No. Offices, a large 216m² Refectory (with dishwashers, sinks, fridges & seating accommodation), a Store room, Switch room, male & female WC's and shower facilities, a 135m² Drying room, a 135m² Locker room, a Lobby with Reception area and a Security room. 2 No. corridors with stairwells and a DDA Compliant lift were installed to take employees to the first floor of the structure. The first floor features a huge 665m² open plan Office, 5 No. additional Meeting rooms, a Communications room, open plan fully-fitted Kitchen/Dining area, Casual Meeting space and male & females WC's.

In total the project was designed, manufactured and installed in just 14 weeks with dramatically reduced on site traffic and site disruption. This was extremely important to Network Rail as the building is situated next to a live railway.

Network Rail - Stockport
2012 Olympic Games TV Studios - London

2012 Olympic Games TV Studios - London

  • Client - Star Events Ltd.
  • Project size - 36m²
  • Completion - 14 weeks
  • Television Studios for NBC News
  • Brushed aluminium single-glazed laminated 2m x 0.75m windows set to a 10° angle

Star Events Limited has been supplying equipment and services to the events industry for over 38 years, delivering stages, structures, seating and rigging for some of the world's most high profile events as well as for a vast array of smaller community and commercial events. Star Events Ltd required a company to provide two Television Broadcasting Studios for NBC News in the Olympic park during the 2012 London Olympic Games. Module-AR Limited were awarded the contract to design, manufacture and install the TV Studios due to our past experience in the Office sector and our ability to provide a range of diverse projects with a short lead time.

The buildings were for temporary purposes and therefore were clad in Plastisol (plastic coated steel) and were constructed with Polyflor XL vinyl flooring for a maintenance-free, secure & hard-wearing structure. The modules were sat on a 2m high platform which resulted in a large external steel staircase needing to be erected to allow the Television Studio team to access the building.

A double entrance steel external door opens up into the TV Studios, which were fitted with a 3.4m internal ceiling height and Heat & Cool air conditioning. The glazing requirements were extremely strict as the Studio windows had to be large brushed aluminium single-glazed laminated windows starting at 0.75m above floor level and 2m tall. The windows were set to a 10° angle (to prevent the cameras picking up reflections of the studio lighting) and internal fluorescent lighting was installed giving the building a professional studio appearance.

With Module-AR Limited installing the studios in just 1 day, this helped minimise site traffic to the busy Olympic park. A total project completion time of 14 weeks was all that was required - up to 50% faster than if the project was completed traditionally.

2012 Olympic Games TV Studios - London
Bristol Royal Infirmary

Bristol Royal Infirmary

  • Client - University Hospitals Bristol, NHS Trust
  • Project size - 490m²
  • Completion - 11 weeks
  • 6th Floor Rooftop Extension - Surgical Assessment Suite
  • 15 No. Consulting rooms, 9 No. Changing areas & Reception
  • Demolition & Removal of existing 6th Floor Structure
  • 'Optimo Self-Clean KS1000' Kingspan cladding
  • Factory-fitted Brise Soleil

Module-AR Limited were sub-contracted by Halsall Construction Ltd. to provide 16 No. modular units suitable for installing on the sixth floor of the Bristol Royal Infirmary. Before the installation of the Module-AR Limited structures could commence, Module-AR were firstly required to demolish and remove the existing corrugated, and asbestos-clad, structure on the sixth floor of the King Edward building.

Upon removal of the old structure, the 16 Module-AR bays, externally clad with 'Optimo Self-Clean KS1000' Kingspan, were then craned into position on top of the King Edward building and a linkway was erected to the existing building. The windows of the modules were fully hinged to permit cleaning from the inside and protective barriers were installed, along with a fall arrest system, for safe external maintenance of the structure.


Inside, the Bristol Royal Infirmary modular building is utilised as a Surgical Assessment Suite with 15 No. Consulting rooms, 9 No. Changing Areas, Reception rooms, a large Patient Waiting Area, Clean & Dirty Utility rooms and WC facilities. Factory-fitted brise soleil was installed to maximise sustainability, reduce sun glare and optimise natural light into the building. Due to the site being in the centre of the city of Bristol, construction site space was minimal. Alongside this, the modules were to be delivered on top of a busy hospital so minimising site disturbance was essential. The 16 No. modules were craned into position over 2 days without ever blocking the emergency entrance into the hospital and causing minimal disruption to the Hospital's daily activities.

In total the project was designed, manufactured and installed in less than 11 weeks which allowed the hospital to utilise the facility up to 50% sooner than if the building was constructed traditionally.

Bristol Royal Infirmary

What our customers say

"Module-AR worked efficiently and communicated well with the school.They really wanted to understand what our needs were, and successfully met them."
Woodhill Primary School
"Module-AR designed a building that followed our architects’ specification delivering a high quality and easy to maintain building which operates well for the Elland Road Park and Ride patrons."
Paul Hammer – Engineer, Leeds County Council
"The Module-AR team worked professionally and hard in order to get the modular buildings ready in time, as they were needed in an emergency. All of the staff were polite/courteous and have worked with the premises team well."
Michelle Fenniche - Executive Head Teacher, Forster Park Primary

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