Case Study: Whiston Hospital

Orthopaedic Theatre Conversion with UCV

Demolition & Strip-Out

The project began with the full strip-out of an existing general theatre. MET implemented comprehensive surveys and isolations to protect adjacent live theatres. Works included removal of redundant services, partitions, and finishes, all sequenced to minimise disruption. Dust, noise, and vibration were strictly controlled, with barriers, HEPA-filtered negative-pressure zones, and daily monitoring to ensure patient safety.

Building & Structural Works

Following demolition, MET undertook building and structural modifications to accommodate the new orthopaedic theatre. This involved forming new structural openings, installing supports for the Ultra-Clean Ventilation (UCV) canopy, and enhancing fire compartmentation. All penetrations and openings were coordinated with structural engineers and validated against fire and acoustic strategies.

Clinical Finishes — MET HPL Walling System

The treatment room walls were lined with MET's bespoke High-Pressure Laminate (HPL) system. This provided a durable, hygienic, and seamless finish essential for infection prevention in orthopaedic theatres.

Seamless, impact-resistant panels with flush junctions, eliminating ledges for dust accumulation.
Coved skirtings and sealed interfaces to ensure easy cleaning and spill containment.
Flush-integrated accessories and service panels, maintaining a sterile environment.
Vision panels with integral blinds, designed to maintain clinical privacy while ensuring compliance with infection control standards.

Mechanical, Electrical & Specialist Installations

Installation of a new Ultra-Clean Ventilation (UCV) laminar flow canopy, validated to HTM 03-01 standards.
Full mechanical installation, including HVAC plant, ductwork, chilled water, heating, and BMS integration.
Electrical distribution, IPS/UPS systems, lighting (general and task), fire alarm, nurse call, and data systems.
Integration of specialist equipment: pendants, surgical lights, Theatre Control Panels (TCPs), PACS panels, and laser lock-down systems.
NICEIC-certified electrical testing and commissioning.

Health & Safety Management

Principal Contractor duties under CDM 2015, including supervision, competency checks, and supply chain vetting.
Daily briefings, toolbox talks, and dynamic risk assessments to ensure worker and patient safety.
Strict noise, dust, and vibration controls due to adjacency of live theatres.
LOLER-compliant lifting operations for canopy and plant installation, with detailed lift plans and exclusion zones.
Fire safety management including hot works permits, temporary detection isolation, and fire watch protocols.

Quality Management

Comprehensive Quality Plan including Inspection & Test Plans (ITPs) for all work stages.
Mock-ups and sample approvals for finishes, including HPL walling system junctions and pendant/light positioning.
Progressive inspections with sign-offs at key stages, reducing defects at handover.
Material and product compliance checks with CE/UKCA declarations, DoPs, and full certification logs.

Environmental Management

Site Waste Management Plan with >95% diversion from landfill achieved through segregation and recycling.
Use of low-VOC adhesives, sealants, and finishes to improve indoor air quality.
Energy-efficient UCV canopy operation modes and LED task lighting to reduce ongoing energy demand.
Sustainable material selection, including FSC®-certified products within the HPL walling system.

Commissioning & Validation

The theatre underwent rigorous commissioning and validation before handover. UCV performance was tested with smoke visualisation, recovery time testing, and particle counts. Electrical systems were validated against HTM 06/08 standards, and radiation shielding was certified by the appointed RPA. Stakeholder witness testing was carried out, ensuring clinical acceptance before operational use.

Outcomes & KPIs

Zero RIDDOR incidents throughout the project duration.
Zero unplanned downtime in adjacent theatres, ensuring uninterrupted surgical activity.
Validated UCV performance exceeding HTM 03-01 criteria.
Snag-free handover with complete O&M manuals, staff training, and integrated CAFM data for the PFI provider.

Relevance to Lot 4

The Whiston Hospital project demonstrates MET Healthcare's expertise in delivering complex, high-value (£5m–£15m) healthcare refurbishments under JCT Design & Build contracts. As Principal Contractor, MET managed demolition, building, M&E, and clinical installations within a live hospital setting, while ensuring compliance with HTM/HBN standards, quality management, and environmental best practice.

Live Theatre Continuity & Accelerated Programme

Throughout the works, MET successfully maintained continuous operation of the two theatres located adjacent to the construction zone. This was achieved through:

Robust dust-tight partitions, negative pressure containment and HEPA filtration to protect sterile environments.
Careful sequencing of noisy and vibration-heavy activities, scheduled outside of surgical hours.
Temporary service diversions and connections to ensure uninterrupted supply of power, ventilation, medical gases and nurse call systems to live theatres.
Close daily liaison with clinical teams and Infection Prevention & Control (IPC) to validate environmental safety before each shift.

By adopting an accelerated delivery model, MET completed each theatre refurbishment within a 12-week programme. This was achieved through extended working hours, parallel trade coordination, and just-in-time delivery of specialist equipment. Despite the fast-track nature of the programme, all safety, quality, and compliance requirements were maintained, ensuring zero disruption to ongoing surgical services.