Stoke MDU
Project Overview
Stoke Maintenance Delivery Unit (MDU) was awarded as a Design and Build contract to Cleshar and is one of several pilot contestable schemes introduced by Network Rail as part of its ‘open for business’ procurement and delivery model. “Contestable projects are funded projects that can be delivered by parties other than Network Rail, where it is safe to do so. This is different to the normal contracting process because some elements of the delivery manager role, currently delivered by Network Rail’s capital works delivery teams, will be offered to the market as part of the contract.” By putting work out to market in this way and working with new supply chain partners, Network Rail aims to increase innovation and efficiency and save a potential 30% on its £200m MDU portfolio.
The whole project was designed and delivered by Cleshar (GRIP stages 4 to 8) with the objective of ‘decluttering’ the current site, removing outdated accommodation and providing the optimum whole life MDU to support enhanced collaborative and integrated working for all Network Rail staff. The works were managed in a ‘high street’ environment with no impact on the operational railway.
Scope of Works
Following the enabling works, ground investigations and surveys, the works comprised the construction of:
1. Multi-purpose building (860m2)
• Offices, meeting, and briefing rooms
• Welfare/staff facilities including toilets, showers, changing, locker and drying rooms, kitchens and mess rooms
• All utilities including power, water, and sewerage.
2. Warehouse building (450m2)
• Material and plant storage
• Office and welfare facilities
• All utilities.
3. External areas (5000m2)
• Access roads
• Parking for 80 vehicles and concrete aprons
• Electric vehicle charging points
• Waste recycling facilities
• Electrical substation (DNO)
• 325m3 attenuation tank, 3no. Klargester pumping stations and 2no. interceptor units
• Fencing, gates, lighting, CCTV, and access control.
Key to the smooth-running and successful outcome of the project was sustained collaboration with all stakeholders, in particular, Network Rail staff as the end users of the MDU to ensure that their requirements and expectations were considered and agreed.
A series of stakeholder group meetings led by Network Rail’s project manager were held, based on schedules and drawings produced by Cleshar, to facilitate the decision-making process. From this, Cleshar was able to develop concise schedules of requirements, providing three priced options on which the stakeholders could then make their own informed decisions, approval could be sought and the project moved forward.
Cleshar used Structurally Insulated Panels (SIPs) for the structure, a low carbon and cheaper system which also provides the advantages of high insulation, off-site manufacture and fast on-site installation. SIPs are not commonly used within Network Rail and, to meet fire standards’ requirements, additional timber laminated timber restraint beams were integrated into the design based on the fire test data and structural requirements.
Innovations
• The Stoke MDU project provided Cleshar with the opportunity to work for Network Rail as a tier 1 building partner for the first time.
• Early stakeholder involvement in the project during the design stage resulted in layout acceptance and sign off of the agreed schedule of stakeholders’ requirements within 30 working days.
• The staged approval of designs allowed phased construction to start before design completion, resulting in a start on site 10 months early.
• Off-site prefabrication of construction/fit out components ensured better accuracy and high quality finishes.
• Phased possession and hand back of areas within the operational depot allowed Network Rail activities to continue normally.
• Phased completion of the works resulted in early completion of the critical utilities’ works and warehouse building before the main MDU facility.
• Matterport scanning software was used to provide virtual ‘walk throughs’ of the MDU works in progress and at completion.
Benefits / Project Outcome
Stoke MDU is an exemplar contestable project for Network Rail and Cleshar, which has provided Network Rail staff with enhanced accommodation and a working environment conducive to improved welfare and well-being.
Collaboration was key to providing the best project outcomes, minimising delays and additional costs and enabling a smooth handover and ‘bringing into use’ of the new facilities.