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Modular Hospital Wards

New Multi‑Storey Modular Ward Delivered at Royal Shrewsbury Hospital

ModuleCo has successfully delivered a modular multi‑storey ward at Royal Shrewsbury Hospital, working in close partnership with The Shrewsbury and […]

Apr 2026
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We are delighted to introduce Professor Phil Begg who recalls his experience of the Royal Orthopaedic Hospital Birmingham modular Operating Theatre and Ward facility. The complex consists of 4 Laminar Flow Operating Theatres and a 20-bed ward, all delivered using industry-leading modular construction techniques and was handed over to the Trust on December 14th 2020.

With over 40 years of experience in the NHS, a Clinician, Clinical Researcher and Academic, and as the Director of Strategy and Delivery for one of the most established hospitals in Britain, I think you can safely say that I’ve committed myself to a life of learning.

This last year, the curve may have been steeper than most; the only difference as I write this today, is there has seldom been a time when our health and well-being has been the top of everyone’s agenda – ironically, if you work in the NHS, there is never a time when it isn’t.

Now I’m remarkably fortunate, the very place where I work is a Grade 2 Listed Building, steeped in history; once owned by the Cadbury family, this fabulous 11-acre site has successfully brought together a number of Orthopaedic Hospitals which have been in existence for a staggering 203 years.

With that history, naturally comes the design and architectural challenges of facilities which, let’s just be polite and say, were very much ‘created for their time’, grown organically and spun-up-as-and-when they were needed from 1907 to 1990. Fast-forward to today and when we were faced with the necessity of creating a new facility at the ROH, that design legacy cocktail presented some very real obstacles.

Pretty close to the top of the list, is the way the Operating Theatres are built, which is essentially in clusters of three and each cluster run by a shared plant and machinery; so, if anything breaks, you instantly lose all of them. Being a small but very productive Hospital that focuses just on Orthopaedics, the productivity and financial impact of losing three Theatres is significant, to say the least – but equally not an isolated issue.

The new facility was planned to be set at the very centre of the Hospital where it had the potential to cause the greatest level of disruption. Someone (it may have been me) coined the phrase that we were essentially performing heart surgery on our own building. Adding to its uniquely awkward position, you have the Theatre complex on the right-hand side, the Ward Blocks straight ahead and to the left, the Residency and Out-Patient Department, all surrounding the very area we needed to replace.

All we had to do was get permission, remove over a thousand tonnes of earth, ferry huge lorries and five hundred tonne cranes, in-and-out of a small kidney-shaped car park and then build four new operating theatres and a twenty-bed ward at the heart of a working hospital – Oh and without causing any disruption.

As a consequence, it wasn’t long before the option of traditional construction was eliminated. Along with a shopping list of logistical challenges, it became abundantly clear that route could also take anywhere up to two years and the costs were simply implausible.

Now, whatever your experience of modular buildings, I can tell you they are not the same animal they once were. In fact, if you’re lucky like we were and meet a group of people who genuinely put the patient’s recovery at the centre of their designs, then you are essentially presented with a blank canvas to create a quality, leading-edge (and indeed a more versatile) facility than any traditional build.

When we met the team at ModuleCo, we already knew they had a healthy track record and history for providing premium healthcare facilities and modular buildings to the NHS but what set them apart was their level of credible confidence in approaching a project of this complexity.

There was, however, also the issue of money…not only is the NHS under exceptional pressure this year, with Capital Expenditure being squeezed from all angles, this was not going to be an easy ask, but together with the team at ModuleCo Healthcare, we agreed a two-phase approach where we could effectively lease the facilities by leveraging revenue generated by the Hospital over a 10-year period.

And it was genuinely that simple, we had ‘zero’ capital expenditure on ‘day one’ and a clear path forward to build two state-of-the-art Operating Theatres, Anaesthetic Rooms, a six-bed Recovery Unit and half of a 20-bed Ward attached to our existing Theatre block.

Together as a team, Phase One of the project was delivered on time, including two premium Theatres, twelve beds on the first floor (two-four bedded bays) and four single rooms and with little-to-no-disruption to the Hospital at all, which to this very moment, I still view as a remarkable accomplishment by everyone involved.

Within a matter of weeks, Phase One was so successful that we initiated the launch of Phase Two, so as of 14th December, we have four brand new, state-of-the-art Theatres, a twenty-bed Ward with eight rooms (in two blocks of four) and the remaining twelve are single rooms with their own en suite bathrooms. The facilities are such high quality, they promise to revolutionise our patient experience, bringing me nicely to where this all began.

I fundamentally believe that both health professionals and patients share a common desire and that is faster and successful recoveries. For that to be a possibility, it is essential the stage is set correctly and this is where I believe the Royal Orthopaedic Hospital is the most extraordinary organisation I’ve ever worked for.

From the front-line care-workers to the Chief Executive, you won’t witness any project or initiative embraced, unless we all understand the impact it has on patient care, and with our most recent work, we’ve taken that quality to a different level. Every last aspect of our new facility is designed to support a quicker and successful recovery and I would defy anyone to walk inside and identify them as modular buildings.

The Operating Theatres are so exceptional, we have surgeons quite literally queuing up to use them – The recovery rooms include noise reducing features, regulated temperature, and no sign of the vibrating floors associated with typical modular buildings. Between us, we have created the optimum conditions for the recovery of the patients in our care. That’s something to be proud of but equally, as far as I’m concerned, it’s also just the beginning.

What we have achieved together as team is a genuine sense of accomplishment through authentic collaboration and a blueprint for future projects. Today, when ModuleCo sit in on our project meetings, there are times we agree on all points and days that we don’t, that’s what great partnerships are made of but this much is also true – we are both unrelenting in our commitment to quality patient care and the evidence now sits at the very centre of the ROH for everyone to see.

If this facility was like performing surgery at the very heart of our building, then it is perhaps very fitting that its creation was born from the well-being of our patients, alive at the very heart of its endeavours.

About the Author

Professor Phil Begg is the Executive Director of Strategy and Transformation for The Royal Orthopaedic Hospital Birmingham NHS Foundation Trust. He has over 40-years of experience working in the NHS and is an Honorary Professor in Life and Health Sciences at Aston University. Phil played a critical role in delivering the combined Operating Theatre and Ward complex and kindly authored this article on behalf of ModuleCo.


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Modular Hospital Wards

Operating on the Heart of the Hospital

Jan 2021

We are delighted to introduce Professor Phil Begg who recalls his experience of the Royal Orthopaedic Hospital Birmingham modular Operating […]

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We are delighted to announce that ModuleCo and our partners at The Royal Orthopaedic Hospital have been award ‘Off-Site Project of the Year’ at the 2020 Building Awards.

The 2020 building awards were held virtually this year, with the winners announced live on www.building.co.uk on Tuesday 3rd November 2020.

We are so thrilled to have won off-site project of the year and are delighted to continue delivering top-quality projects to clients across the UK.

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Construction Industry

ModuleCo Honoured with National Award

Nov 2020

We are delighted to announce that ModuleCo and our partners at The Royal Orthopaedic Hospital have been award ‘Off-Site Project […]

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Let’s be honest, whether it’s the life-altering three months earlier this year or the three weeks to come, any lockdown period is not without its challenges – particularly when the choices you make could have a profound impact on the UK’s front-line healthcare workers.

I know this first-hand because back in February this year, when we were encountering the early murmurs of a pandemic, I began researching the potential risks of ‘High Consequence Infectious Diseases’ (HCID) and it didn’t look pretty. At that particular moment in time, the UK had just four facilities in total designed to deal with such an outbreak; two in London, one in Manchester and one in Newcastle – with just two beds each.

Weeks later, a full lockdown ensued and concerns about the NHS’ capacity to cope and beds available, began to flood the media headlines. For the first time, I had major concerns we could come under immense pressure to close our own business, when ironically the facilities we provide, could make a significant difference to the very health workers which needed the help.

Like many professions, the majority of people who work in the Construction industry aren’t viewed as key workers and equally don’t have the option of picking up a laptop and working from home. Worse still, in the case of ModuleCo, if we elect to stop work, our ability to help the NHS Trusts would be rendered redundant at the worst possible time.

Truth be told, the next three days were spent on back-to-back on phone and Zoom calls with our supply chain, many of whom were ready to shut-up-shop until the pandemic had blown over. We asked, pled, negotiated, cagouled, encouraged and incentivised every last key worker and reached an agreement that together, we wouldn’t put the Trust at any risk.

That turned out to be easier said than done – After bolstering our social distancing policies, PPE equipment and extending (our already) stringent hygiene policies, we also realised pretty quickly that we’d barely scraped the surface of what was really needed. Providing a safer work environment was just the beginning.

Our intentions at the time may have been about preserving and protecting our NHS clients but it was far from a ‘straight-forward ask’. We weren’t simply requesting people to pitch-in a few extra hours – many of our in-house team (and our contractors) had vulnerable relatives whose health could be put at risk, simply as a by-product of us continuing to work.

I spoke individually with every single employee and contractor who needed to play an integral part in delivering the Trusts facility and quickly decided that traditional commercial acumen would have to take back seat for now. We agreed to offer every key skilled worker full-board accommodation, seven days a week and increased many people’s financial compensation in recognition of their personal commitment.  

I’m proud to say that we kept our promise to Stoke Mandeville and didn’t lose a single day on the project. Our next job, however, is to begin to educate how we can further empower our NHS Trusts, as we move forward into the next phase of tackling this pandemic together.   

Arguably, Modular Construction has earned its place at the table this year by creating the ‘Nightingale’ facilities for the NHS to deal with any capacity issues – The principle of providing additional resources was undoubtedly the right thing to do but the execution and choice of structure was unfortunately, remarkably short-sighted.

Millions of pounds of funding have been spent on ‘Temporary’ Modular buildings which are essentially ‘Single-use structures’ with all the quality and sustainability values of a discarded Glastonbury tent. Aside from the odd machine, they also carry zero asset or residual value and the likelihood of them being simply scrapped in the near future is remarkably high – This is as much a travesty, as it is completely avoidable.

At ModuleCo, our team has worked hard to change the perception of Modular Construction and modular hospital design by creating premium facilities which are designed to ‘Put the Patient’ first. We focus purely on creating an environment which supports successful and quicker recoveries – a clear and shared desire of both healthcare workers and patients.

A forward-thinking Modular hospital design is not a short-term strategy and is designed to reduce noise, vibration and provide a consistent temperature – all qualities synonymous with successful recoveries and equally, often more robust than even traditional construction.

As we enter into the second phase of the pandemic, it is our job to help NHS Trusts understand that they don’t have to compromise on the quality of their working conditions and if we’re to truly empowering our healthcare professionals, then it’s critical that together, we set the stage for the best possible patient experience.

I’m not sure I’ll ever forget the first three months that changed the face of our world. Some people say that saw it coming, others say that it was a surprise but I do know this much; when it comes to supporting and standing shoulder-to-shoulder with our NHS Trusts, for us, it has, and will continue to be, business as usual.

William Thornton, CEO of BRG Technologies

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Construction Industry

Building Trust with the NHS

Nov 2020

Let’s be honest, whether it’s the life-altering three months earlier this year or the three weeks to come, any lockdown […]

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We are delighted to announce that ModuleCo and our partners at The Royal Orthopaedic Hospital have been shortlisted for the 2020 Building Awards. ModuleCo’s Multi Theatre and Ward Complex has been nominated for ‘Off-Site Project of the Year’.

Jo Williams, Chief Executive Officer at ROHNHST, said: “[The facility] will allow us to offer more of our world-leading orthopaedic care to local people and provide a state-of-the-art working environment for our staff.”

The awards will be held virtually this year, with the winners of each category being announced live on www.building.co.uk from 4pm on Tuesday 3rd November 2020.

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Construction Industry

ModuleCo Nominated for National Award

Aug 2020

We are delighted to announce that ModuleCo and our partners at The Royal Orthopaedic Hospital have been shortlisted for the […]