Modernising surgical and support facilities to meet growing demand
NG Bailey supported the £27m redevelopment at Darlington Memorial Hospital, delivering new operating theatres and a modern mortuary facility to enhance surgical capacity and improve patient experience.
The existing theatres were over 35 years old and no longer aligned with modern standards. The project involved the construction of a new extension housing six state-of-the-art theatres, alongside the upgrade and expansion of existing theatre facilities.
Each new and refurbished theatre includes integrated systems such as replacement lighting, clean air and power supplies, as well as enhanced laparoscopic equipment to support less invasive procedures and reduce patient recovery times.
Delivering new-build and refurbishment works within a live clinical setting
The project included full MEP installation across the new theatre and mortuary block, alongside a complex phased refurbishment of the existing operating theatre suite, day surgery areas, recovery spaces and Ward 14.
A variation to the original contract also incorporated the refurbishment of the MRI suite, extending the scope of delivery. To facilitate the new development, site-wide enabling works were undertaken, including infrastructure upgrades and the demolition of an existing three-storey building.
Maintaining hospital operations through phased delivery and detailed coordination
Maintaining live hospital operations throughout construction was a central challenge.A phased delivery strategy was developed and continuously refined in collaboration with the Trust and Integrated Health Projects (Vinci), ensuring that the majority of existing theatres remained operational at all times.
This approach was supported by detailed surveys of existing services, careful coordination within live clinical environments, and a structured logistics strategy designed to minimise disruption to staff and patients.
Using BIM and offsite manufacturing to improve coordination and reduce risk
All services were designed and coordinated using BIM (Revit), enabling full integration between design, manufacture and installation. This approach supported the delivery of offsite manufactured solutions, including ceiling modules, plantroom modules, pipework spools and an offsite-constructed electrical switchroom, improving quality, reducing on-site labour and lowering risk.
Driving value through collaboration, innovation and early engagement
Early involvement, spanning approximately 18 months prior to site works, enabled detailed surveys, coordinated BIM modelling and informed design development. Close collaboration with Integrated Health Projects, RPS and the wider project team supported value engineering, including a revised plantroom strategy that reduced programme duration, minimised disruption to existing structures and lowered overall project risk.
The strength of this approach led to additional scope being awarded, reflecting confidence in delivery and collaboration.
Delivering enhanced facilities for patients, families and staff
The new mortuary replaces a 45-year-old facility and includes a bereavement centre, quiet room and dedicated family spaces, providing a more appropriate and supportive environment. The upgraded and expanded theatre facilities enable the Trust to carry out a greater number of procedures, reduce waiting times and minimise patient stays, improving overall healthcare outcomes.
Creating safer, more efficient healthcare environments with minimal disruption
Through a combination of phased delivery, BIM-led coordination, offsite manufacturing and collaborative working, complex works were delivered within a live hospital setting. The approach reduced risk, maintained continuity of care, and provided modern, high-quality facilities that support the hospital’s long-term operational needs.
