Cann Hall Primary School

A fully enclosed scaffold structure was erected to protect the works from adverse weather conditions. Existing roof-mounted pipework was removed and relocated internally, while the existing waterproofing, insulation and RAAC roof deck were removed and disposed of off-site.

A new profiled steel roof deck was installed onto the existing steel frame, together with new fire breaks at all compartment wall locations. The replacement roof was completed using a Bauder warm roof waterproofing system, comprising a vapour control layer, tapered PIR insulation to create drainage falls, and high-performance waterproofing membranes.

New triple-skin polycarbonate rooflights were installed to match the existing openings.

Internally, extensive refurbishment works included the installation of new M&E, incorporating upgraded ventilation systems throughout. The school kitchen was fully stripped out to enable the RAAC removal and to allow for the installation of new flooring. Upon completion, all kitchen equipment was reinstated and recommissioned.

Further improvements included the installation of new suspended ceilings with mineral fibre tiles, complete redecoration throughout, and the replacement of existing carpet and vinyl floor finishes.

Externally, the existing trim trail was removed, and the area reconfigured to eliminate level changes. New trim trail equipment and safety surfacing were installed.

Following completion, all temporary facilities, services and access routes were removed, restoring the sports field to its original condition. The scaffold enclosure was dismantled, and repairs and redecoration works were carried out to the school façade.

Construction Processes and methods

• RAAC concrete was removed across the whole school; a new metal roof deck was designed and installed to replace the RAAC, and fire stopping was installed into the profile of the metal decking before a new ply deck was installed over.
• New 3-layer Bauder roofing system over tapered insulation with falls to the perimeter where new outlets were installed in the roof upstands; our brief was to remove the need for all internal downpipes.

Challenges and Constraints

• The project required that we work around a live primary school; all works have been carefully planned and executed to ensure that the pupils were never put at risk and that working areas were totally sealed off from the live school, safe fire routes were maintained throughout and daily communication with the school proved invaluable.
• Access to the roof working areas proved challenging as there was only one route down for all of the removed roofing and RAAC concrete, and one route up for all the new materials; scaffold erection and removal also needed careful planning.
• The school is on a main road, meaning deliveries and contractor parking were challenging; these were exacerbated during school drop-off and collection times.
• It was crucial that the school could operate effectively and safely throughout the works; this meant that during the M&E strip-out in the various phases, the live classrooms and school offices were not affected and that the electrical, mechanical, communication, door entry and fire alarm systems remained fully functional

Environmental and Ecological

• Waste segregation/repurposing/recycling
• Local labour was key to the success of the project; most of the trades were within a 25-mile radius, the site carpenter lived 50 yards from the site, and the project manager lived 2.3 miles from the site
• ECO cabins have been used for our site welfare that are fitted with LED lights on PIR sensors, door closers and smart heaters that detect if doors are open and shut down; water butts were fitted to the temporary portacabins for rainwater harvesting; this was used to maintain the school plants, etc.
• As ISO 14001-accredited, we carried out environmental risk assessments, minimised waste, and ensured licensed disposal, with around 90% recycled.

Lessons Learned and Project Outcomes

• The project has been delivered successfully, receiving positive feedback from all involved.
• The fully enclosed scaffold proved invaluable, significantly contributing to programme certainty and enabling works to progress efficiently.
• Consistent and proactive daily communication with the School was instrumental in maintaining strong stakeholder relationships and ensuring the smooth delivery of the project.
• Early engagement with subcontractors to establish expectations, responsibilities and project requirements was critical to achieving successful outcomes and maintaining high standards throughout the works.

Social Value

• The contract employed mostly local labour, either directly or indirectly. 3 FTE were directly employed for the duration of the contract, and 87% of the supply chain were/are local.
• Excellent communication with local residents via letter drops and regular talks with the teachers and pupils
• Site visits were provided for members of the public
• The site team gave an assembly to the students informing them of the works in progress.