South Molton Scaffolding Ltd has successfully completed a technically challenging temporary roof and access project at Petroc College in North Devon, overcoming significant logistical and structural hurdles to deliver the scheme ahead of schedule and on budget.
The project involved the design and installation of a fully encapsulated Haki roof system over Block A of the live college site. The work was essential to allow for the safe removal and replacement of defective Reinforced Autoclaved Aerated Concrete (RAAC) within the roof structure.
Operating within a live educational environment brought unique challenges from the outset. The site was small and congested, with tight delivery windows and the requirement to maintain access to surrounding buildings, footpaths, disabled ramps, and occupied ground-floor offices.
South Molton worked closely with the project’s structural engineers and Raptor Scaffold Design & Consultancy to overcome site limitations. Key measures included:
- Ground investigations to assess load-bearing capacity
- Installation of compacted hardcore for kentledge
- Redesign of beam supports due to hollow roof parapets
- Steel RSJ installation to take the lateral load and tie back to the internal structure
Due to the client’s request to avoid disturbing the metal cladding, traditional drill-in ties were ruled out. Instead, the team adopted a combination of increased kentledge, buttresses, and band-and-plate ties at low level to the surrounding brick walls. This was further reinforced by an internal birdcage scaffold tied back to the external scaffold via opened windows, enhancing overall stability.
Safety, Speed and Sensitivity
A key driver in the project’s success was the use of the Haki system roof, which allowed 80% of the structure to be pre-built at ground level and craned into place. This greatly reduced work-at-height exposure for operatives. UK System Scaffold Hire provided materials and support for the roof system.
The team also installed a Haki staircase to reroute pedestrian traffic, and an integrated drop chute scaffold extension was constructed to accommodate 26-yard skips for demolition debris. All lifting operations were carefully scheduled at weekends to avoid public disruption.
Despite an initial two-week delay caused by design changes, South Molton’s team accelerated works on-site, ultimately completing the job four days ahead of the original 12-week programme.
Recognition for Excellence
The contract was delivered on time, within budget, and even included a number of free-of-charge client extras. Feedback from Pearce Construction and Petroc College’s head of maintenance praised the team’s professionalism, planning, and consideration throughout.
Raptor Scaffold Design, responsible for final sign-off, commented: “Overall, the scaffold has been built to a very high quality and the scaffolders should be commended for the work they have put in.” The site received 100% marks on health and safety inspections, including those conducted by the principal contractor and South Molton’s own external advisors.
Reflecting on the achievement, South Molton Scaffolding’s Director said: “My job is to understand the brief, win the work, and plan it – but it’s the guys on the ground who brought this complex project to life.
Their professionalism and determination were key to its success.”
The project marks a standout achievement for the Devon-based contractor, showcasing both technical capability and an unwavering commitment to quality.
