My project

I’m responsible for the Salt Grammar School project, part of an £84m PFI scheme being delivered by Educo UK (a joint venture partnership between Costain and Ferrovial Agroman). All three schools are due for completion in summer 2008 following a 74-week construction programme.

The build faces a stern challenge due to the site being a natural conservation area - the school is opposite the historic Salts Mill while ancient woodland forms the northern boundary. Co-ordination with the boundary fencing (issues include overhanging tree branches and achieving a Secured By Design ‘sign-off’) and a surface water drainage ditch has already proved testing. With the drainage we are restricted by the fact that plant can’t operate within a 6m zone of the trees, meaning hand digging only, although again there is a one metre restriction.

The decanting of existing buildings and the split level design incorporating a substantial retaining wall along the entire length of the building further enhance the project’s complexity. Although the decant isn’t being managed by Educo UK, there are several design and programming aspects that require careful management. Firstly, we are working to a very challenging decant period with very little ‘float’ or margin for error. Secondly, the fact that the existing school is made up of multiple buildings will prove problematic, especially the existing 6th Form Block - because of its location it prevents seamless continuity in the building process. It cannot be demolished until a temporary facility is constructed, an intrusive asbestos survey and any remedial actions are undertaken, and the building is assessed for the presence of roosting bats.

The retaining wall is required to harmonise the split-level ground floor design with existing site levels while preventing unnecessary excavation. An enormous structure, it features individual panels in excess of 5m in height. From a project point of view it adds to the complexity due to specific programming, delivery and installation requirements. From a procurement perspective we have to design the panels, approve and manufacture them in a pre-determined fabrication ‘slot’.

Prior to their arrival we need to have completed complicated ground works including piled foundations, pile caps and concrete bases for the supporting props. Pre-cast panels need to be installed and supported before an insitu concrete toe beam can be formed. This concrete toe then needs to cure and achieve an acceptable 28-day strength before the area can be tanked, the necessary drainage runs installed and the whole area back-filled.

Following closely behind are the steel erectors who will install the steel beams and columns as well as pre-cast concrete floor planks. After this we need to cast the ground and edge beams. All of these activities are sequential and could delay another activity therefore careful co-ordination and effective process management is crucial in hitting target dates.

Delivery and installation of the pre-cast concrete retaining wall panels will also be tough. Weighing in at around 10 tonnes each, only 2 panels can be accommodated per delivery and due to the site logistics these need to be installed directly from the back of the delivery lorry.

The most interesting aspect is the personnel. Made up of English, Spanish and Portuguese staff, the challenge is to work efficiently and effectively whilst drawing from very different knowledge bases is both fascinating and rewarding. Relatively new to the UK market, this is Costain partner Ferrovial’s first active involvement in a construction project here. However techniques and past experiences shared by its staff are proving highly beneficial at the workface and both partners learn from each other. A mixed workforce on each project also helps to further reinforce the team ethic and joint venture attitude.

As far as the spoken language is concerned, the Ferrovial employee’s grasp of English is far better than their counterpart’s grasp of Spanish and Portuguese! Whilst technical phrases and terminology may prove to be difficult to understand, the project team have developed an early and clear understanding, and very few problems are being experienced. It is anticipated that the working relationships being developed now will remain strong for many years to come.