Project Overview

State of the art changing facilities for Exeter College Rugby Academy.

client

Exeter College / Exeter Chiefs

location

Exeter | Devon

category

requirements & challenges

The works comprised the construction of face brickwork and 140mm blockwork to the internal and party walls throughout the building. These elements formed both the structural and aesthetic components of the project, requiring precision, coordination, and attention to detail to achieve a high-quality finish.

  • Restricted Site Access. The site presented significant logistical challenges due to its confined layout. With only a single access point available through the front of the property, all materials — including bricks, blocks, and mortar — had to be manually transported through the building. This restriction made mechanical handling extremely difficult and necessitated extensive hand-loading, which in turn slowed progress and increased manual labour demands. Careful planning was essential to sequence deliveries and material movements efficiently while maintaining site safety.
  • Seasonal Constraints. Construction commenced late in the year, with colder and wetter weather conditions impacting both productivity and working methods. Additional precautions were required to protect materials from frost and moisture, maintain mortar workability, and ensure consistent quality despite the challenging environment. Progress rates were naturally slower due to shorter daylight hours and the need for greater control over curing and laying conditions.
  • Material Characteristics – Staffordshire Engineering Brick. The use of Staffordshire engineering bricks introduced an added level of complexity. These bricks are extremely dense and have a very low water absorption rate, which, while beneficial for durability and appearance, makes them more difficult to work with in colder weather. The lack of water absorption affects the bond between the brick and mortar, requiring increased attention during laying to achieve proper adhesion and prevent joint failure.

solutions we provided

Despite the combination of restricted access, challenging weather conditions, and the demanding nature of the materials used, the project was delivered successfully through careful planning, close supervision, and a strong emphasis on quality control. The experience reinforced the importance of proactive logistics management and adaptive working practices when operating under tight site and environmental constraints.

Efficient Material Movement. Given the limited access, pallet trucks were utilised wherever possible to transport materials through the building. Once inside, bricks and blocks were manually distributed to work areas and onto scaffolding. This systematic approach ensured a steady flow of materials to the workforce despite the logistical constraints.

Enhanced Material Protection. All Staffordshire engineering bricks were kept completely dry to maintain quality and workability. Strict storage procedures were enforced, with all materials covered and protected from rain and ground moisture at all times. Deliveries were timed to reduce on-site storage durations and avoid unnecessary exposure to adverse weather.

Adjusted Working Methods. Working methods were adapted to suit both the weather conditions and the characteristics of the materials. Mortar mixes were closely monitored and adjusted as necessary to improve adhesion and workability. Bricklayers were briefed on handling techniques specific to engineering bricks, ensuring consistent quality across the build.