The Castle Hill Hospital New Day Surgery Unit was a key project in Taywel Engineering’s timeline, requiring precision engineering, expert problem-solving, and seamless execution. Awarded the main steel structure package in January 2022, our team took on the challenge of fabricating and installing over 400 tonnes of structural steel in Phase 1 alone.

Project Overview Phase 1

📅 Timeframe: 16 weeks for the main steel structure

💷 Project Value: £1.4 million

🏗 Steel Installed: 400+ tonnes

Our scope of work included detailed design, fabrication, delivery, and installation. The steelwork was manufactured in 22 lots, carefully coordinated to align with the project’s phased construction timeline.

Overcoming Site Challenges

The project’s stepped foundations posed a significant challenge, limiting access for cherry pickers and cranes. Our team adapted the lifting plan, increasing crane locations and deploying larger cherry pickers to improve reach and accessibility. This strategic adjustment ensured that installation stayed on track without compromising safety or efficiency.

Expanding the Scope

As the project evolved, design modifications added an additional 60 tonnes of structural steel to support the ceiling grid and plant, along with:

🔹 Two large external staircases

🔹 A ramp totaling 35 tonnes

Taywel Engineering also handled internal steelwork, including:

🔹 Aluminium chequer plate wall sheeting

🔹 Key clamp handrails

🔹 Fibreglass flooring for walkways and stairs

Precision & Efficiency

Our team’s commitment to accuracy and efficiency resulted in the main steel frame being completed nearly two weeks ahead of schedule. With a manufacturing error rate of less than 1.5%, the project showcased our dedication to high-quality engineering and meticulous execution.

Looking Ahead: Phases 2 & 3

With Phases 2 and 3 underway, an additional 450 tonnes of steel will be installed, along with two large staircases, ramps, and walkways, adding another 70 tonnes to the project.