London School RAAC Removal and Replacement

PROJECT PROFILE

London School RAAC Removal and Replacement

INTRODUCTION

Reinforced Autoclaved Aerated Concrete (RAAC) has emerged as a pressing concern across many properties and sectors throughout the UK, including schools, highlighting the gravity of issues facing some educational institutions. Initially lauded for its lightweight and cost-effective properties, construction companies used RAAC extensively in public buildings, including schools, from the 1950s to the 1980s. However, the material has shown signs of deterioration over the years, sparking safety concerns among the construction industry, educational authorities, parents, and policymakers.

CREATING SAFE SCHOOLS

RAAC Removal in an Education Setting

Acknowledging RAAC's vulnerabilities has prompted an immediate nationwide evaluation of school buildings. Inspectors have identified issues such as reduced strength, susceptibility to water ingress, and potential structural failures that pose significant risks to the safety of students and staff.

In light of these challenges, we will explore the specific problems associated with RAAC as they have manifested in this school building, the measures taken by educational authorities and government bodies to address these issues, how Starfish Construction Group divisions worked in tandem across the project phases as a single source principal contractor, and how effective measures to restore trust in the school’s infrastructure ultimately led to the project’s success.

DURATION

14 weeks

AREA OF ROOF REPLACED

450 m²

Our Expertise

UNI ROLLING ROOF SHEETING SYSTEM

The client is an inner-city London Comprehensive co-educational academy for students aged 11–18. A survey identified RAAC within the gym hall roof. The School Trust, a previous client of Starfish Construction, invited us to tender a solution for the RAAC roof removal and replacement works. The scope of works included:

Removal of the existing roofing system, including unexpected screed and bitumen layers, and the RAAC panels
Installation of new steel beams (fan supports) and a new TATA steel deck
Installation of a new Langley roofing system
Installation of new roof fan units, lighting, and speaker system
Upgrade of the roof safety system to facilitate future maintenance requirements

RAAC REMOVAL PLANNING

Starfish Construction's single-source principal contractor approach begins by meticulously analysing all existing design information related to the roof's build-up. Our comprehensive technical surveying review approach enabled us to design and develop a robust structure to support the new roofing system.

We conducted various surveys to inform the design process, including intrusive roof surveys, research and development surveys, and drone surveys. These assessments provided the necessary data to finalise the design. Structural engineers were engaged to oversee these elements, ensuring the structural integrity of the design and facilitating smooth progress once on-site work commenced.

Given the project's school building location, our team laid out extensive planning to ensure safety and professionalism. We installed an internal scaffold crash deck beneath the existing RAAC roof, mitigating risks associated with potential falls and securing the building's contents against any large sections of RAAC that might break free. Externally, the Starfish Access and Scaffolding in-house Division erected scaffolding around the perimeter and a uni-rolling roof sheeting system. This setup protected the work area from inclement weather and minimised noise and dust disruptions to the school and its pupils.

CREATING SOLUTIONS FROM OBSTACLES

Project Challenges and Adaptations

During the removal phase, the team encountered several unexpected anomalies in the roof's build-up, which meant adapting the design and further safety considerations.

These adjustments were crucial in maintaining the project's momentum and ensuring roof integrity and safety. The project also faced significant variations, including designing, supplying, and installing new fan systems, lighting systems, and a three-phase power supply.
One of the most demanding aspects of the project was when the client requested that we complete the work two weeks earlier than planned to accommodate the upcoming GCSE exam schedules. This request, coming several weeks into the project, posed a significant challenge, especially considering the additional work already underway. However, our team rose to the occasion, devising an action plan that included increasing labour, extending daily working hours, and implementing weekend shifts. Our concerted effort was instrumental in ensuring the hall was available for the GCSE exams.

The London school project involved removing RAAC from the gym hall roof and replacing it with a new roofing system
The project included installing new steel beams, a TATA steel deck, a Langley roofing system
Roof fan units, lighting, and an upgrade to the safety system
Starfish Construction used comprehensive surveys and planning to ensure safety and minimal disruption
In-house group scaffolding and access division created innovative roof protection system
The project faced challenges, including unexpected roof anomalies and a request to complete work early for GCSE exams
Completed ahead of schedule, the project received high praise from the client and the Department for Education.

Our success

UNINTERUPTED EDUCATION AND EXAMS

Despite the significant challenges and additional work requirements, we completed the project two weeks ahead of schedule which delighted the client. This project showcases Starfish Construction's single-source service capability and dedicated commitment to delivering high-quality results under demanding circumstances.
This pioneering DfE-funded RAAC removal and replacement project, the first in the education sector, was a litmus test for Starfish Construction and the broader UK education property portfolio. The project's exceptional outcome, rated A+, showcases the expertise of our integrated divisions and their end-to-end building safety solutions.

As a single-source principal contractor, our turnkey solutions provide a single point of contact for reporting and communications. Our site team managed every project element with up-to-date, transparent and accessible online information for designated stakeholders, mitigating commercial and Health & Safety risks.

SCHOOL AND PROPERTY MANAGEMENT FEEDBACK

I want to be the first to offer my thanks for the exceptional way in which this project was delivered. I understand it is always a team effort, so thanks to all who are involved. On behalf of the Trust, I want to express our utmost satisfaction with the way this project has been managed. It stands as yet another outstanding example of our ongoing relationship with Starfish Construction and their highly professional team. SB - Trust Director

The client’s property management and surveyors closely monitored the project, scoring us across the project. Starfish Construction achieved an incredible 10/10 across all scoring categories, a remarkable achievement for our team. 

"Starfish Construction employees were always courteous and polite and explained the work in a way we understood before the work started. They kept us informed at all stages of the work, taking steps to protect and respect our property and contents, together with a minimal environmental impact, keeping disruption and disturbance to a minimum. Starfish Construction completed the work safely to the agreed timescale. We were happy with the quality of workmanship and the finished installation and were always able to contact Starfish Construction's staff if necessary, with queries/complaints dealt with in an efficient and prompt manner. We were very satisfied with the overall service we received."

BUILDING ENVELOPE

ROOFING

CLADDING

TECHNICAL SURVEYING

The DfE is extremely pleased that the RAAC has now been removed from the school and has been very impressed with the way you and the Trust have handled the project.

Thanks to your comprehensive updates, I'll be sharing this good news story and photos with internal colleagues who have been keen to see the final result.

Of the significant number of schools contacted at the end of August regarding DfE's change in approach to RAAC, your project is the first to have completed the full removal of RAAC. Ministers are keen to keep abreast of the progress of removing RAAC from schools, and this will undoubtedly be reported to them. 

DEPARTMENT FOR EDUCATION