Faced with the challenges of providing modern welfare amenities in a demanding, remote quarry environment, the project required a facility that could meet rigorous health and safety standards while offering comfort and functionality for the workforce. This case study explores the design, manufacture, and installation of a large prefabricated modular welfare facility.
Aggregate Industries’ Torr Works Quarry, located near Shepton Mallet in Somerset, is one of the UK’s largest limestone quarries. Spanning approximately 205 hectares, the site has been operational since the 1940s and plays a pivotal role in the region’s construction industry.
Torr Works produces around 5 million tonnes of limestone aggregates annually, supplying materials essential for construction projects, particularly road building. Notably, about 70% of the quarry’s output is transported by rail to depots in South East England, significantly reducing road traffic and associated environmental impacts. The new welfare facilities were strategically positioned next to the quarry rail depot, giving staff easy, safe access to the rail operational hub.
Modular prefabricated welfare facilities have become an increasingly popular solution for construction sites and quarries. These units provide essential amenities such as restrooms, changing areas, canteens, offices, and first-aid rooms, designed to be quickly deployed, expanded and easily relocated as projects progress, ideal for dynamic quarry sites with changing layouts.
Prefabricated units eliminate the need for costly, time-intensive on-site construction. Constructed from robust, weather-resistant materials, these units are built to last, reducing long-term maintenance expenses. They perform well on compliance and comfort, meeting health and safety regulations, whilst the modern design includes insulation, climate control, and ergonomic layouts to ensure a comfortable environment for workers. Modular facilities can be customised to include specific features, such as shower facilities, secure storage, or office space.
TF Jackson installed a plug-and-play 18-unit welfare facility in just two months, from design to delivery. The multi-unit complex included office space, full hygiene facilities and a new training room. Specific features included:
Externally, the unit was cladded in pressure-treated timber to meet Aggregate Industries’ objective of blending in with its natural surroundings. Dusk-to-dawn light sensors were installed to control outdoor lighting whilst conserving energy.
The unit perimeter was fenced by a robust Armco safety barrier system, designed to protect staff and the building from the heavy vehicles and equipment routinely operating in a working quarry. Other safety features include signage and an external staircase with anti-slip treads and landing plates, handrails and hi-vis black and yellow nosings.
Aggregate Industries is committed to sustainable practices at Torr Works, landscaping over 80 hectares with grass and trees to blend with the natural surroundings, supporting the creation of bio-rich environments and maintaining its own 27-acre reservoir to augment local watercourses.
Acquiring a modular prefabricated building is a highly sustainable choice for companies looking for a more eco-friendly construction. Built in controlled factory environments, they significantly reduce material waste compared to traditional methods. These structures use energy-efficient materials and can incorporate renewable technologies like solar panels or rainwater harvesting systems. Their quick assembly on-site minimises disruption and lowers carbon emissions associated with transportation and construction. Additionally, modular buildings are designed for flexibility and reusability, allowing components to be relocated or repurposed, extending their lifecycle.
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