Petroc ‘Animal Care Centre’ sees modular modernisation
Petroc College, a leading institution in North Devon, needed to replace its outdated animal care centre to keep up with its expanding curriculum and student needs.
The goal was to deliver a modern, purpose-built facility with specialised animal housing that was cost-effective, durable, and could be installed swiftly over the summer break to minimise disruption.
Mister Modular proposed an innovative solution using refurbished, or ‘donor,’ modular frames, reconfiguring existing steel structures to fit the college’s specifications.
Over 18 weeks, the new facility was assembled on-site, seamlessly integrating with the campus and featuring a sleek, modern cladded finish.
The new building greatly enhances the learning environment with state-of-the-art classrooms, laboratories, and animal housing, setting a new standard for future campus developments.
About Petroc
With a rich history that spans over 60 years, Petroc has established itself as a cornerstone of education in the region, serving a diverse community of over 6,000 students annually.
One of the standout offerings at Petroc are its Animal Care courses, which provides students with hands-on experience and expert instruction in animal welfare, management, and conservation.
Project Details
The project included removing old modular structures and constructing a facility designed for around 60 students, featuring specialised areas for diverse animal species, from rodents to lizards.
Using donor frames sped up the process, removing the need for costly and time-consuming modular framework fabrication.
The new centre covers approximately 400 square meters and features five classrooms for specific animal types: rabbits & guinea pigs, small mammals, aquatics, tropical species, and arid species. Each room has custom housing to ensure the animals’ safety and comfort.
The building also includes an office, veterinary room, WC, kitchen, pantry, and storage, providing comprehensive facilities for students and staff.
Reflecting Petroc’s commitment to sustainability, the facility features eco-friendly elements such as energy-efficient HVAC systems and eco-friendly insulation – which reduce environmental impact and operational costs.
The project was led by Cornwall-based modular buildings consultancy Mister Modular and supported by local contractors.
Challenges & Solutions
Challenges Faced
Petroc required the new facility to be operational quickly to avoid disrupting student and staff programmes. The timeline was further shortened by the need to demolish old structures and prepare the site.
While staying within budget was crucial, the focus was on delivering a high-quality facility. This led to the adoption of innovative modular construction techniques that balanced cost and quality.
The project also had to meet various regulatory requirements, including building codes, environmental standards, and educational facility guidelines. The Mister Modular team expertly navigated these challenges to ensure the modular design was both compliant and functional.
Innovative Solutions
To address the challenges of ageing infrastructure and tight timelines, modular construction was chosen as the optimal solution by Petroc’s procurement team.
Mister Modular proposed reusing existing modules, which dramatically reduced construction time and allowed completion during the summer break. This approach effectively halved the typical construction duration by avoiding lengthy lead times for new modules.
The donor modular frames, though nearly perfect, were adapted to fit specific site conditions and space constraints. Jackpad supports were employed to optimise space and ensure the facility was both functional and visually appealing.
Prefabricated modules led to substantial cost savings. Besides the frames and joists, all other materials were newly purchased from local suppliers, benefiting Cornish businesses.
Timeline
The project began with a collaborative design phase led by Petroc and Mister Modular’s design team. Key steps included:
Design
- Needs Assessment: Evaluating the specific requirements of the Animal Care courses, including classrooms and specialised facilities like animal treatment rooms, outdoor kennels, and veterinary labs.
- Custom Modular Design: Developing a tailored design using existing donor modules, which were reconfigured to meet the project’s space requirements efficiently.
- Client Collaboration: Conducting regular reviews with Petroc College to align the design with their functional and aesthetic needs.
Siteworks
- Site Clearance: Demolishing outdated buildings and preparing the site for new construction, including ground levelling and stabilisation.
- Foundations: Installing Jackpad foundations to provide a secure, environmentally friendly base for the modular units.
Logistics & Installation
- Logistics Coordination: Planning module delivery and transportation to ensure timely site arrival.
- Module Assembly: Using HIAB cranes to position and connect modules, resulting in a weather-tight structure ready for interior work.
Interior Fit-Out
- Flooring & Insulation: Installing 22mm floor-grade hardwood plywood, Rockwool insulation, and Armstrong hydro board ceilings.
- Interior Finishing: Fitting Whiterock wall coverings and Tarkett Granit Safe.T flooring for durability and ease of maintenance.
Exterior & Utilities
- Exterior Work: Applying anthracite cladding and soffits for a modern look. Installing CCTV, fire detection systems, and outdoor animal enclosures.
- Utility Installation: Setting up electrical, water, and specialised drainage systems for the animal care requirements.
- Final Inspection & Handover: The project concluded with a thorough inspection to ensure quality and functionality before officially handing over the facility to Petroc.
Results
Time Efficiency: The project was completed 40% faster than traditional methods, significantly reducing disruption and allowing Petroc College to start using the new facility sooner.
Cost Savings: Delivered within budget, the use of donor frames and modular methods saved on manufacturing and labour costs. Off-site manufacturing also brought economies of scale and reduced waste.
Enhanced Learning Environment: The new facility features five state-of-the-art classrooms, a veterinary simulation room, and both indoor and outdoor animal care areas, greatly improving the learning experience for students.
Sustainability Achievements: The project incorporated energy-efficient HVAC systems and other eco-friendly features to minimise environmental impact and operational costs.
Supporting Local Contractors: Mister Modular and Petroc College supported the local economy by sourcing materials and services from regional suppliers, ensuring high-quality craftsmanship and community engagement.
Bill Blythe, Vice-Principal at Petroc College:
“We are thrilled with the outcome of the Animal Care Centre modernisation project. The new facility not only meets but exceeds our expectations in terms of functionality and design.
The state-of-the-art classrooms and specialised animal care areas provide our students with a truly exceptional learning environment. The swift completion and efficient use of modular construction allowed us to minimise disruption and stay within budget, which was crucial for us.
The commitment to sustainability and local suppliers was also greatly appreciated, aligning with our values and enhancing the overall success of the project.”
Conclusion
The modernisation of Petroc’s Animal Care Centre showcases the effectiveness of modular construction in delivering a modern, cost-effective, and sustainable facility.
The project’s success sets a benchmark for future campus developments, highlighting the benefits of innovative construction practices in meeting evolving educational needs.
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