Rosyth Frigate Assembly Hall

Our works consisted of drainage, large pile caps and ground beams, a module hall ground floor slab, and external concrete hardstanding slabs.  The scope included:

• Significant structure spanning 160m in length, 60m width, and 40m height, to accommodate two 138.7m vessels weighing 6,000t.
• Layout design accommodates manufacture and repair of two vessels side by side with open access and egress at either end of the building.
• North and south facade vertical-lift megadoors, 24m wide by 30m high, with a demountable column between. 
• Materials included 8500m3 of structural concrete and 2500t of rebar. 
• Two rail-mounted gantry cranes oversailing the full internal floor area. 
• Gantry staircase within the structure, mitigating the requirement for scaffold and enabling personnel to safely access the vessels. 
• Collaborative lean thinking design approach to ensure best value, meet budget expectations and to future-proof the building.
• Extensive design and supply chain engagement including several trial pours to achieve concrete specifications of core compressive strength, abrasion and freeze thaw resistance, and finish. 
• Challenging high cement content requirement to achieve strength and abrasion resistance.
• BS 8500-1, BS 8500-2 and BS EN 138772-2 standards. 
• Excavation, structural fill and infrastructure constructed to MCHW Volume 1: Specification for Highway Works.
• Royal Navy Ministry of Defence contract necessitating high level security checks for all personnel.
• Bespoke security procedures and protocol briefed to all staff.
• Logistically challenging delivery adjacent to the dockside at Rosyth.