Rapid Installation
The modular units were installed in just one day, thanks to a tightly coordinated delivery and craning schedule. This efficient approach ensured minimal disruption to the school’s daily operations, even while demolition and enabling works were being carried out on-site. The new facility includes general teaching classrooms, sensory space, and SEND-specific accommodation, providing flexible, inclusive, and purpose-built learning environments for pupils and staff.
Comprehensive Turnkey Package
McAvoy delivered a comprehensive turnkey package that included all aspects of the project lifecycle. This ranged from early site surveys and investigations through to demolition of the existing modular buildings, groundworks, foundations, utility connections, manufacture, transport, and full internal fit-out. The works also involved external reinstatement and landscaping, ensuring the site was left clean, safe, and fully functional.
Challenges
Through collaboration across design, operations, and logistics teams, a Swept Path Analysis was carried out to overcome the site’s access challenges. With limited space and tight entry points, McAvoy used fully remote rear steer trailers to manoeuvre the eight modules through narrow pinch points to the crane pad. The entire operation was meticulously planned and delivered by our specialist logistics team, ensuring a smooth and safe installation.
Minimising Disruption
Throughout the programme, McAvoy prioritised safety, communication, and minimising disruption. The site was fully segregated using Heras fencing with debris netting.
This project demonstrates the value and versatility of McAvoy’s offsite construction solutions in a live school environment. Delivered on time, on budget, and installed in just one day, the new modular facility at Hetton Lyons School provides long-term educational value while showcasing the speed, quality, and safety of the SmartClass® system.
Social Value
Pupil engagement was built into the programme through assembly presentations on construction safety and careers in the built environment. These sessions encouraged curiosity, inclusion, and learning, while also highlighting pathways into the construction industry. In addition, McAvoy prioritised local supply chain involvement where possible, supporting the regional economy and leaving a positive legacy beyond the delivery of the new school building.
SmartClass®
A key feature of the SmartClass® system is its superior fire performance and compliance credentials. Each module delivers a 90-minute fire rating from floor to floor and a 60-minute rating from inside to outside.
The building envelope uses A2-rated non-combustible cladding, insulation, and roofing systems, exceeding regulatory requirements and providing peace of mind to both the school and the trust. The modular design also incorporates level access to negate the need for ramps, tactile paving at entrance points to assist visually impaired users, and a ventilated void below the structure to meet damp prevention requirements under Building Regulations.
