Offsite construction specialist, Caledonian Modular, has completed a multi-million pound project for Petrofac in the Shetland Islands. Caledonian built high quality modular accommodation and amenity buildings for the 850 workers who will be constructing a new processing plant at Sullom Voe for the Laggan Tormore gas field being developed by Total 140 miles offshore. With no local builders able to meet the one-off demand of such a large project and with site wind speeds frequently over 100mph, this was always going to be an ideal project for offsite modular construction. Also, when the new gas processing plant is completed in around four years’ time, the modular buildings can be deconstructed and relocated anywhere in the world.
The lack of local amenities meant that Petrofac had to plan to build a complete temporary ‘village’ including restaurants, health facilities and a convenience store in addition to living accommodation. Caledonian Modular was awarded the £21m contract by main contractor, Malthus, which specialises in remote accommodation for the oil and gas industry. The project includes 424 twin bedrooms in five interconnecting hotel-style blocks, a 3,200m² amenity block, and 4,000m² of office and welfare facilities. All buildings have been designed and built to meet Scottish Building Regulations, with enhancements to meet the site’s severe climatic conditions, including winds sometimes topping 140 mph.
The various buildings for the ‘village’ were constructed from a total of 482 modules. Offsite content was maximised to enhance efficiency and quality, and reduce on site works. External cladding and roofing panels were installed in the factory with simple site joints designed to minimise potential loss of time on site due to high winds. Most of the interior fit-out was also completed in the factory. Bedrooms were supplied with all furniture, en-suite bathrooms, and carpets installed prior to delivery. Any additional materials required on site were loaded into the modules before transportation.
Stephen Wightman, Caledonian Modular’s Director of Business Development, comments, “The Shetland project demonstrates the unique benefits of offsite modular construction, particularly in terms of meeting the logistical challenge of providing a range of buildings in such a remote location. During the critical phase one build, the project took up 350,000ft² of factory space, spread over two of the company’s four factories at Newark in Nottinghamshire, and two of the three factories at Driffield in Yorkshire. We believe that no other modular facility in the UK could have managed this level of build, making this an impressive example of Caledonian’s capabilities and the scope and versatility of modern offsite construction technology.”
For more information go to www.caledonianmodular.com.
