A total of 1,425 modules in light steel framing was installed over a four month period on the Wilslow Park site of Manchester University to create the largest modular building in the UK and probably in the world. The 7-storey modular building was constructed on a steel-composite ‘podium' structure at first floor, which housed retail promises and a car park below ground. 

The super structure above podium level was originally conceived in timber framing, but was later replaced by a modular steel solution.

The modular suppliers, Rollalong, worked closely with their architects, The Design Buro, to offer a design which could be completed in a narrow ‘window' from February to September 2002, in time for the new intake of students. This speed of manufacture and installation would not have been possible in any other form of construction.

The design Buro already had experience of the Ayrframe system used for manufacture of the modules on the nearby Royal Northern College of Music, and produced all the working drawings for manufacture and interfacing with other components.

Rollalong commissioned a purpose-made factory in nearby Wythenshawe and in a few months was able to set up a sophisticated ten-line production of modules over an eight day cycle of boarding, servicing and fit-out before delivery to site.

The modules formed 945 study bedrooms, and communal areas used pairs of open-sided modules to create larger spaces. A strict quality assurance ‘passport' and locked door policy ensured that the modules were checked before installation and were immediately fit for use.

The ‘mixed' residential-commercial development also incorporates retail outlets, a health club, 130 key worker apartments (for rent) and six rooms for people with disabilities. The retail and car park levels were designed using primarily steel frame to a column grid based on pairs of modules on the upper floors.

The same team is working on other schemes involving a range of steel and modular technologies for the urban residential sector.

Construction details

The modules use the Aryframe system, which comprises a grillage of C and top hat sections to create an extremely stiff structure with narrow walls. The modules were designed as self-supporting over seven storeys. Manufacture permitted variations in the façade arrangement, and corridors were also integrated into the modules. Standard modules of widths from 2.4m and 3.6m were arranged in three, four and five bedroom clusters around kitchens and communal areas, which were also manufactured modules. Coridors in-built within the modules reduced the site work and achieved weather tightness during construction. An integrated modular stair and lift shaft was also important innovation for this project.

The podium structure on which the modules were placed consists of long span I beams actingtogether with a composite slab on steel decking. The light weight of the modules was important in order to economise in the design of the podium structure. The 175mm deep composite slab supports the loads from the module walls where they do not align directly with the beams below.

The installation procedure for the modules used a ‘man basket' system, which was approved by HSE as being the safest method of working at height. A peak installation rate of 28 modules a day was achieved by the 9 man team over the 4 months of the production and installation period on site. Manufacture through-put averaged 10 modules per day on a 8-day production cycle in Rollalong's purpose-made factory nearby. This is the first example in the UK of such a facility sep up for one project.

The ‘rain-screen' cladding system was selected in order to achieve the rapid-build programme. It generally consisted of terracotta tiles on a sub-structure fixed through the cement particle board facia and back to the modules. On the courtyard area, an aluminium rainscreen cladding was used.

Key information

Number of storeys	7
Modules	1425
New-build home

    World's Largest Modular/Steel Framed Building in Manchester