London Hospital Mammogram Pod

Innovation overview and development

Provide an overview of the product
The Innovative Product is a free-standing, timber framed mammogram pod installed into the basement of a listed building in London. The pod was constructed using re-useable, panelised frames, filled with recycled denim insulation, and boarded with a combination of 3D laminated MDF tiles, glazing and Knauf Safeboard to provide radiation shielding. Lead-lined swing and sliding doors offered safe access and were custom-designed to ensure nothing was fixed down into the base-building walls, floor or ceiling. The walls of the pod were designed for disassembly and pre-constructed with power and plumbing containment. A glulam timber frame was designed and pre-cut, offering structural support to the joists above which were experiencing deflection three times the permitted amount. Inside the pod was a floating floor and laboratory-grade suspended ceiling, topped with a ply lid, to maintain required air flow in the room. The pod was also fitted with custom casework and deep IPS unit, housing a waste pump to distribute water to the permitted penetrations in the listed building walls.

How the new product was developed, including effective collaboration, knowledge transfer and partnership along the project team
The requirements brought about by the operation of the pod, the nature of the prefabricated system, as well as the location in which it was being installed meant that collaboration amongst all the relevant stakeholders was necessary from the onset.

Architectural Wallsz was initially approached by the Architect on this project, requesting free-standing, radiation shielded mammogram pods, inclusive of glazing, flooring and ceilings, integrated power, data, plumbing and casework. Once a concept was outlined, weekly design review meetings were set up with the architect, main contractor, client, M&E contractors, structural engineers and AWallsz to ensure full transparency of design and allocation of responsibilities.

Throughout the project, AWallsz sought consultation from external designers, structural engineers, electrical specialists and the clinical scientist who wrote the Radiation Protection Advisor (RPA) report, as well as regularly verifying their design submissions with the manufacturers of the walls and doors.

The wall system is comprised of prefabricated, panelised aluminium frames and pre-finished boards. These modules are manufactured to size and populated with any internal power, data and technology containment before they arrive on site. For this reason, all the decisions need to be made up-front, in the design stage, to ensure quick and clean installation on site.

Upon receipt of the RPA report from the Architect, the team initially began investigating ways of shielding the existing wall system whilst still retaining the opportunity to integrate the services within the wall, and without fixing in any way to the base building floor, ceiling or walls. It was after engaging an external design company, the decision to use Safeboard was agreed, along with the design of the floating floorboards on dry levelling compound on which to lay the vinyl flooring. The internal face of the walls could remain as removable MDF panels with cut-outs for services, whilst the external walls provided the shielding required for the machines. Working in collaboration with the door manufacturers, AWallsz were also able to develop compliant door specifications that met the RPA requirements without fixing to the base building.

AWallsz worked closely with the client and electrical engineer to determine the exact location and operation of electrical boxes, providing detailed drawings and visuals and walking through the space in Virtual Reality to confirm.

Later in the design stage, the client’s structural engineer found that the equipment and pod on the floor above would cause excessive deflection in the building’s existing joists and AWallsz recommended incorporating a structural timber frame to the pod which could be used to support a steel beam running across the top and prevent the ceiling from deflecting more than the permitted amount. Throughout this time, AWallsz engaged in structural design discussions, both with the Manufacturer and the client’s structural engineer. A design was agreed and signed off by all parties, and the solution was installed.

How might this product have an influence on the specification
Upon realisation of the deflection issue in the building, the specification was ammended to include a steel goalpost structure to provide the support. This would have meant time-consuming and wasteful cutting and welding on site, and the result would have been unsightly and industrial. The AWallsz timber framed pod was a more sustainable and efficient solution which offered the necessary structural support, in keeping with the aesthetic and functional features of the pod. The timber frame was fabricated to size off-site and was installed in just three hours on site.

The original specification featured power and data running under the floor and on face-mounted trunking along the walls. Using the AWallsz multitrade system, these services were easily installed within the cavity of the walls, behind removable panels, maximising space and maintaining infection prevention and aesthetics. This also replaced the requirement for a raised floor to house the electrics, which would have reduced the internal height of the pod.

Using Safeboard offered a more cost effective and lightweight alternative to lead lined walls and glazing, whilst still meeting the requirements set out in the RPA.

Provide details on how the product improved productivity in the process and/or quality and performance of the interior system
The main improvements brought about by the pods are as follows:
– Speed and efficiency on site: By making all the decisions in the design phase and constructing the majority of materials off-site, the client benefitted from significantly reduced labour times, what’s more, there were no variations once the order was placed. Using pre-finished materials and modular frames where possible, wet trades and cutting down on site was minimised.

– Sustainability: The client has benefitted from a fully reconfigurable, relocatable system, constructed of recycled aluminium and denim insulation. The pods are designed for disassembly, meaning it can be reused and reconfigured elsewhere throughout its lifetime, reducing the impact of single-use construction materials designed to end up in landfill. The Timber Frame construction results in less waste material, less energy and is considered more carbon neutral than many other materials, contributing to its sustainable nature. All of the wood is sourced from sustainably managed and harvested forests (FSC or PEFC).

– Structural Support: The use of prefabricated timber beams accommodated the structural requirements to ensure stability, and maintain the integrity of the historical building. This solution was also in keeping with the aesthetic qualities of the prestigious healthcare organisation.

– Improvement of operation and comfort: The original room allocated to mammography in the hospital was a large, open space with high ceiling and grand windows. Though impressive in it’s style, it was not appropriate for it’s purpose. Mammograms are intimate and uncomfortable for clients. Large rooms with solid wood floors and high ceilings add to that discomfort so the pod was used to create a smaller room inside to provide a more clinical, intimate and private environment. Doing so also allowed scope for full integration of services, Distribution boards and creative lighting, without damaging the listed infrastructure.