Modular Nursery Build – A Fast and Efficient Solution

Introduction

When Whitchurch Pre-School in Reading needed a new building, they faced a significant challenge. Their existing timber structure was deteriorating, with a leaking roof and a rotting frame making it increasingly unsafe. With time constraints due to the needs of parents and staff, they required a modular school building that could be built quickly and efficiently while still meeting their exact specifications.

After researching options, they found that many modular classroom solutions lacked full turnkey service. That’s where OffPOD came in, offering a steel frame modular construction system that could deliver a high-quality, sustainable, and customisable nursery building within their strict timeline.

The Project Timeline – Delivering in Just Under Seven Wee

Week 1: Demolition and Groundworks

The project began with the complete demolition and removal of the existing pre-school building. OffPOD efficiently cleared the site in just three days, ensuring minimal disruption.

Following this, essential groundworks were completed in just two days day. This included trenching for utility connections, installing a soakaway for rainwater drainage, and preparing the site for the foundation system. OffPOD’s precise scheduling allowed multiple tasks to be completed simultaneously, significantly reducing potential downtime.

Week 2: Efficient Ground Screw Foundations

Traditional concrete foundations can take weeks to set and are highly dependent on weather conditions, often leading to delays. To overcome this, OffPOD utilised advanced ground screw foundations, which offer several advantages:

• Speed – Unlike traditional methods, ground screws can be installed in as little as one or two days, meaning construction can proceed without waiting for concrete to cure.

• Weather Resilience – Ground screws can be installed in virtually all weather conditions, including wet and frosty environments where concrete work would be halted.

• Eco-Friendly – Unlike concrete, which has a high carbon footprint, ground screws produce minimal environmental impact. They require no excavation, reducing soil disruption and waste.

• Strong Load-Bearing Capacity – Ground screws provide a stable foundation capable of handling significant structural loads, ensuring long-term durability.

• Reusability – If a building needs to be relocated, ground screws can be removed and reused elsewhere, making them a sustainable choice.

The pre-build soil tests determined the exact length and type of screws required for the project. The full installation was completed within two days, providing a solid and durable base for the modular nursery build. This rapid installation meant that OffPOD could immediately proceed with the structural framework without any delays.

Week 2-3: Steel Frame Construction

The pre-fabricated steel frame arrived on schedule and was assembled in just 1.5 days. Unlike traditional timber framing, which requires on-site cutting and assembly, OffPOD’s modular steel frames are precision-manufactured in a controlled environment. This ensures:

• Consistent Quality – Factory-controlled conditions mean there are no defects or inconsistencies in the frame components.

• Speedy Installation – Because the steel frame is delivered pre-cut and pre-assembled, it significantly reduces installation time compared to conventional methods.

• Structural Integrity – Steel framing is not susceptible to warping, rotting, or pest infestations, ensuring longevity and minimal maintenance.

  
  

  

  
  

Week 3-4: External Fitout

Whitchurch Pre-School chose an anthracite steel external finish, which is not only durable but also blends into the surroundings over time as climbing plants grow. The external insulated steel wall panels and roof were installed in just three days. The doors and windows followed, taking only one additional day to complete.

OffPOD can complete their builds with a variety of external finish options, including cladding, brick slips, or render, allowing for a tailored aesthetic to suit any project. Additionally, all external elements such as fascias, soffits, guttering, and door/window trims are included as part of the build, ensuring a high-quality and fully finished exterior.

Week 4: Internal Flooring and Underfloor Heating

Inside, the team began installing the insulation and tongue-and-groove (T&G) chipboard flooring. Once the flooring was completed, the wet underfloor heating system was installed throughout the nursery.

Week 4-5: Air Source Heat Pump Installation

A crucial part of the sustainability efforts for this modular classroom build was the installation of an air source heat pump. This highly efficient system extracts heat from the air and transfers it into the underfloor heating, ensuring consistent warmth throughout the year with reduced energy consumption. The installation took two days, including setup and testing.

For pre-schools and nurseries, there may be grants or funding opportunities available to support the implementation of energy-efficient solutions like air source heat pumps. Government schemes, local council initiatives, and sustainability grants can help reduce upfront costs, making eco-friendly upgrades more accessible. Schools and nurseries may also qualify for funding under educational infrastructure improvement programs or carbon reduction initiatives. OffPOD can assist in identifying relevant funding options and provide guidance on the application process.

Week 5-6: Internal Walls, Plastering, and Fitout

With the heating system in place, the team moved on to fitting internal wall insulation, followed by plasterboarding and plastering. This stage took approximately five days, ensuring a smooth and durable finish.

Next, partitioning was completed, creating designated areas for different pre-school activities. This included the installation of child-friendly toilet cubicles and a disability-compliant toilet to meet accessibility requirements. This phase took another three days.

Week 6-7: Internal Decorating and Finishing Touches

After allowing the plaster to dry, the internal decorating phase began. Using durable, easy-to-clean paints, the nursery was finished in bright and engaging colours.

Fixtures and fittings, including storage units and child-safe features, were installed over two days, ensuring a functional and welcoming learning environment.

Week 7: External Decking and Final Handover

To extend the play space, OffPOD installed a high-quality external decking area. This safe, weather-resistant outdoor space provides an ideal setting for outdoor learning and activities. The decking installation took two days.

Finally, a thorough quality check was completed, and the project was handed over to Whitchurch Pre-School on time and within budget.

Why Modular School Buildings Are the Future

This project highlights the advantages of modular school buildings for educational institutions looking for rapid, high-quality, and sustainable solutions. Modular nursery and classroom buildings provide an efficient alternative to traditional construction methods, offering:

• Faster Build Times – With factory precision manufacturing and rapid on-site assembly, projects can be completed in weeks rather than months.

• Sustainability – Features like air source heat pumps and underfloor heating significantly reduce carbon footprints and operational costs.

• Customisation – Modular classrooms can be tailored to specific needs, from accessibility features to energy-efficient designs.

• Cost-Effectiveness – Prefabrication reduces labour and material waste, making modular education buildings a financially viable option.

  
  

Conclusion

OffPOD successfully delivered a fully functional, high-quality modular nursery building in just under seven weeks. By leveraging steel frame modular construction and innovative design, they provided Whitchurch Pre-School with a safe, modern, and energy-efficient learning environment that will serve children for years to come.

If your school or nursery is considering modular classroom solutions, OffPOD offers full turnkey services to deliver high-quality, sustainable, and rapid-build modular school buildings. Contact us today to discuss your project!