McAvoy’s recent work on Orsett Heath Academy in Essex – its largest project to date – highlights the use of modular construction to deliver futureproofed educational spaces efficiently
Covering 8,610 sq m, this three-storey secondary school for 1,200 pupils was completed ahead of schedule and demonstrates the impact of offsite manufacturing on large-scale projects.
Commissioned by the Department for Education (DfE) under its Mod C framework, the academy features 209 precision-engineered modules assembled to create modern classrooms, breakout spaces, a performing arts hub and staff facilities.
Extensive external works, including landscaped grounds, car and bicycle parking and sports facilities, set a new benchmark for modular school design.
Work on Orsett Heath Academy became critical after the original contractor went into administration. McAvoy stepped in to ensure the project not only met its objectives but exceeded expectations.
Delivered one week ahead of schedule, the new academy replaces temporary provisions with a permanent, purpose-built facility designed to inspire learning and support the local community.
Challenging site
The logistical challenges of delivering 209 modules to a site with limited access were significant. McAvoy addressed this by partnering with a nearby airfield, so the modules could be transported without disruption from local traffic restrictions.
Onsite, collaboration with Thurrock Council was key, with temporary and permanent access routes coordinated alongside council-led roadworks.
Working closely with local planning authorities and community stakeholders, McAvoy guaranteed that the project met all regulatory requirements. To minimise disruption, key milestones, including the installation of modules, were scheduled during school holidays and quieter periods.
Digital tools
Advanced digital tools were central to the project’s success. Using Building Information Modelling (BIM), McAvoy developed detailed 3D designs that streamlined coordination, enabling automated clash detection and ensuring compliance.
Virtual reality (VR) models brought the designs to life, allowing teams to refine every detail before construction began.
Onsite, wearable technology and 360-degree cameras provided real-time progress updates, while cloud-based platforms centralised project information.
These methods supported transparency and enhanced communication between all stakeholders, ensuring the delivery stayed on track.
Sustainability was a core focus of the Orsett Heath Academy project. Air source heat pumps provide efficient heating and hot water, while 111 photovoltaic panels on the roof generate renewable energy, reducing operational costs and the school’s carbon footprint.
McAvoy’s approach also prioritised waste reduction. By manufacturing modules in a controlled environment, the company minimised material waste while maintaining consistent quality.
Beyond delivering a state-of-the-art school, McAvoy engaged with the local community throughout the project. As part of the Considerate Constructors Scheme, the team achieved an outstanding audit score of 44 out of 45, with initiatives including local job creation, food bank donations and student site visits to showcase the modular construction process. The company’s commitment to creating a legacy is symbolised by a four-phase lock installed at the school, representing the lasting impact of the project on the community it serves.
The completion of Orsett Heath Academy highlights McAvoy’s ability to deliver large-scale, complex educational facilities efficiently and sustainably. By combining advanced manufacturing techniques with innovative technologies and a commitment to collaboration, McAvoy has set a new standard for school construction.
As demand for high-quality, purpose-built educational spaces continues to grow, projects like Orsett Heath Academy demonstrate the untapped potential of modular construction. With adaptability and innovation at its core, McAvoy is shaping the future of educational infrastructure – one ground-breaking project at a time.
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