HMP Dovegate
Uttoxeter, Staffs
| Precast Construction: | PCE Ltd |
| Client: | Premier Prison Services |
| Main Contractor: | Skanska Construction |
| Architect: | Capita |
| Precast Supplier: | Buchan Concrete Solutions |
The Challenge
With an unsurpassed experience in the custodial market, PCE were chosen to construct the first 800 cell `super prison` of its kind in a precast crosswall system. The key factor in selection was the ability to provide our client with a construction methodology that resulted in phased handovers for 14 complete precast concrete superstructures on key milestone dates during an available total build period of just 40 weeks.
Key Benefits
RELIABILTY
The complete construction process hinged on our ability to successfully meet critical deadlines
EXPERIENCE
The vast scale of the project demanded an in depth knowledge of all aspects of precast construction
LOGISTICS
The pace of the programme and the variation in product type required complex logistical planning and detailing phasing of all works
CAPABILITY
An ability to provide 10 in house erection crews to service the peak demands of the construction programme
SAFETY
Internally managed, innovative and efficient safety systems for all build phases
FEASABILITY
Our design development stage support for our precast partners ensured excellent buildability of the design solution
The Project
HMP Dovegate is a Category B prison complex built on the site of a former MoD ammunitions store in Staffordshire. The new prison was built to house over 800 inmates, 600 in a traditional houseblock environment, with a further 200 in a therapeutic zone that provides better inmate development prior to release and advanced care for more critical prisoners.
The complex consists of 18 structures, 14 of which were designed in a precast crosswall system. The main accommodation is split between two main houseblocks with the therapeutic accommodation divided between three small houseblocks, each two storey in height. A series of ancillary buildings divide the 2 zones with PCE responsible for the construction of the critical front end Entry and Works buildings together with all the Admistration, Reception, Visits, Segregation, Healthcare and Kitchen buildings.
PCE's scope of work on each of the precast structures commenced at pilecap level with a precast ground beam system and was completed with the installation of the roof steelwork ready to receive its watertight covering. This complete superstructure service minimised client interfaces and gave certainty to the overall build programme.
A total of over 11,000 precast components were used for the main superstructure construction. Due to the broad end use of the structures the variety, scale of components and build methodology varied dramatically. Houseblock wings consisted of cell size cross wall and floor components together with internal vanity screens to toilet areas. These were faced with a two cell wide external wall that was then clad traditionally. Core areas were more open span with PCE required to complete insitu pours where spans needed to be maximised. Cellular construction did not suit all the buildings and a number of ancillary structures adopted a more open plan design approach, the internal structure taking the form of a concrete frame.
PCE's logistical planning and careful consideration of all safety aspects across a number of concurrently running construction methods was fundamental to the success of the project. At peak, 40 deliveries per day to serve 10 cranes needed to be controlled by PCE's site management team. PCE's expertise allowed us to influence the buildability of the precast and determine safety systems at an early stage during the design process. This meant the elements were manufactured with site constraints in mind, a 'joined up' approach that was invaluable when managing a project of this scale.
The whole build programme, from pile cap of the first Entry building structure to roof steelwork being completed on the last Healthcare structure, was completed inside the client target of 40 weeks.
PCE's experience and expert knowledge was key to the successful delivery and handover of this project, making PCE the leader in precast custodial construction.
