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Kettering General Hospital, Project 55


Kettering General Hospital, Project 55

Project 55 is a new three-storey development, incorporating a 76 bed expansion to the main hospital. Originally a single-storey outpatient’s ward was demolished to make way for Project 55.

Ground floor: A pediatric outpatients department with six consulting exam rooms, and an acute 28-bed medical ward - this is the main entrance to the hospital, chapel and cardiology.

First floor: Intensive Care Unit, 16 beds, with direct access to the hospital theatres.

Second Floor: Integrated Pediatric Unit with a total of 32 beds, including Surgical and Medical Wards, a Pediatric Assessment Unit and High Dependency facilities. Adolescent patients will also have a dedicated area within the unit.

Innovations included:

  • Lean construction techniques and prefabrication methods off site.
  • Pre-fabricated Kingspan AFS System for the Facade.
  • Clean air units.
  • 'Polyuera' sprayed waterproof membrane used on the roof.
  • 'Chemigrid' floor gratings used in the service risers.
  • 'Extensia' concrete used in the floor slabs.
  • The plaster to the internal walls was completed using a new spray applied system.
  • Prefabricated M&E modules used.
  • 'Eco-genik hoarding made from recycled bottles.
  • BRE Smart Waste was in full use on site.

During the preconstruction period, the client's brief was updated and they required additional single bedrooms and beds to the acute care ward, however, they were unable to increase the overall budget or preconstruction delivery period, and the scheme would be at risk if a solution was not available. As a result, we reviewed the entire scheme and explored ways to provide the additional space. As well as reviewing the construction processes and materials, we assisted the Trust in reviewing their specialist equipment schedules, and we successfully found enough efficiencies to deliver the scheme to the new brief and within the original budget and the preconstruction proposal was submitted on time.

During the construction period, the Trust secured a bid to provide a new Chest Clinic. This was to be incorporated within our project and needed to be delivered by the original completion date. We were approximately 4 months away from completion and providing this new unit required some careful planning and consideration. Working closely with our designers and specialist M&E installers to develop a solution that could be provided within the timescales. During a 2 week period we had held a series of meetings with the stakeholders and obtained sign-off, and we developed a strategy to include this adaptation within our original programme. Through collaborative workshops with our designers and supply chain we successfully delivered the new unit as part of the overall scheme.

Project vitals


Kettering, Northamptonshire


Kettering General Hospital




20 December 2010 to 14 March 2013


We work with high profile government and private sector clients, delivering everything from minor property services roll-outs to large complex construction projects.

Construct a three storey extension to the hospital comprising a new Intensive Care Unit, paediatric in and out patients and a Critical Care Unit.