Modular Building News from Yorkon
20/10/2009

Off-Site Construction - Delivering Excellence In Emergency Care

Watford AAUThe new Acute Admissions Unit at Watford General Hospital is now one of the highest performing emergency care services in the country. Here, David Johnson, Director and General Manager of off-site specialist, Yorkon, looks at its construction challenges.

Constructed as part of a £25m ProCure21 contract awarded to Medicinq Osborne, the new Acute Admissions Unit (AAU) for West Hertfordshire Hospitals NHS Trust was built off site by Portakabin subsidiary, Yorkon.  It is now the UK's largest acute admissions unit and has one of the lowest re-admission rates in the country.

The facility is being used to pioneer a new model of care for emergency cases with rapid assessment and consultant-led diagnosis. This approach dramatically reduces the long-term effects of serious conditions such as strokes and heart attacks.

Designed by Murphy Philipps Architects, the AAU provides 120 beds for emergency admissions, two cardiac catheterisation laboratories, diagnostics including x-ray, ultrasound and CT scanning, and a new hospital pharmacy with robotic dispensing.

A New Generation of Acute Admissions Units

Watford AAUAccording to Graham Ramsay, Medical Director at the Trust, "This is the largest of a new generation of acute admissions units and forms part of the Department of Health's new ‘Model of Care' initiative.  Early indications are showing that the service provided in the new AAU at Watford is having a very positive impact and patients have been really enthusiastic about the environment and the service they are receiving."

The building comprises 142 steel-framed modules, which were manufactured and substantially fitted out off site, reducing the programme time by around six months and minimising disruption on this very busy hospital site.  It was craned into position at the rate of ten 14m-long modules per day in less than four weeks, for the final stages of fitting out.

Programme - The Key Driver for Off-site Construction

The key driver for the Trust for this project was time.  The programme from date of order to Medicinq Osborne to handover was just 47 weeks, meeting the Trust's requirements for commissioning, relocation and staff training.  It also generated significant savings on construction preliminary costs.

The off-site approach enabled manufacturing and fitting out the new AAU to begin before demolition works had been carried out on site.  This parallel working reduced the programme by around 50 per cent and allowed the existing building on the site, a postgraduate teaching facility, to remain in use for much longer.

The modular building design was developed to accommodate specialist equipment required for CT scanning and cardiac catheterisation.  Innovative solutions were provided to deliver a reverberation factor of 1 for these departments, and for the M&E installations to meet the requirements of the new model of care.

The Construction Challenges

Watford AAUIt was essential to minimise disruption both to patient care during the build programme and to the surrounding neighbourhood, despite the site being located adjacent to a fully operational A&E department, in a busy residential area, and in close proximity to the football ground.

A blue-light ambulance zone adjacent to the site had to be maintained at all times, a traffic management scheme was implemented and the hospital car park had to be reconfigured to accommodate work on site.

Careful planning and close co-operation between the Trust, Medicinq Osborne, Yorkon and the local highways department ensured the smooth, phased delivery of the modules.

In order to minimise disruption locally, three modules per day were delivered to site before 7am, avoiding the rush hour and accommodating transport restrictions in place within the M25 before 10am.  The remaining modules then arrived on site at hourly intervals.

Detailed Logistics Planning

Key to the successful installation of the building was a detailed logistics survey which was carried out at an early stage.  A plan was then agreed and maintained with constant communication so the Trust could be advised of impending activities.

The success of the logistics programme can be measured by the lack of complaints from local residents, including those immediately adjacent to the hospital, during the module delivery period.

An Exemplar Project for Fast Track Solutions

This was a large, highly complex building required to accommodate specialist medical equipment, and linked to the existing traditionally-built hospital at two levels.

It was handed over on time and on budget, and since its completion, it has further improved the image of modular buildings in the healthcare sector and is being shown within the NHS as an exemplar project for fast track solutions.

Feedback and evaluation from the Trust following its 100-day review indicated that the building has provided significant benefits in the quality of care and the working environment for staff, demonstCranagerating that:

  • Lengths of stay reduced from 7.3 to 5.4 days (average)
  • Reduced readmission rates are now 4.2% (peer group 6.5%)
  • Key performance measures were maintained and in some cases improved
  • Staff turnover reduced from 16.3% to 12.8%
  • Complaint numbers reduced
  • Emergency admissions increased by 10%
  • Emergency attendances reduced by 4%. 

According to Sarah Wiles, Director of Strategy and Planning at the Trust, "We have achieved a fantastic building which it was said would not be possible in the timescale."

Lesley Harrison, Senior Sister in the AAU, concludes, "Patients and staff are very pleased with the new building. The unit is light and airy - a pleasant environment that is much easier to keep clean.  There is lots of space around patient beds which is hugely beneficial when clinical staff are carrying out interventions.  Patients love the bright colours and have even compared it to a hotel!"

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