Ibstock Concrete’s precast division played an important role in the ongoing development of the Alexandra Hospital in Redditch, where main contractor Interclass PLC is delivering a new clinical facility to support the growing demands on the Worcestershire Acute Hospitals NHS Trust.
The project involves the construction of two new operating theatres, recovery areas, staff offices and welfare changing rooms. Construction began in February 2024 and is scheduled for completion by November 2025. Located on a live hospital site, the programme is being delivered at pace and with minimal disruption to surrounding healthcare services.
As part of the new extension, two precast concrete lift shafts were manufactured and supplied by Longley, part of Ibstock’s flooring and precast business. These lift shafts will provide essential vertical circulation between the new operating theatres and adjacent recovery spaces. Due to the complexity of the site layout, limited access and the need to maintain hospital operations throughout construction, a precast solution was selected to reduce installation time and limit site disruption.
Longley provided a full-service solution covering the design, manufacture and installation of the precast lift shafts. Typically produced in five sections, the units were instead delivered in nine self-supporting precast box sections per shaft to accommodate the irregular dimensions specified by the client and to facilitate safe transport and craning into position. Each section weighed up to 6.2 tonnes and was produced with a wall thickness of 200mm, an increase from the standard 140mm, which required bespoke adaptation of the moulds at Ibstock’s precast production facility.
The two lift shafts were installed in a single day, demonstrating the efficiency and accuracy achievable with a modular, factory-built approach. The use of precast also brought significant benefits in terms of health and safety, eliminating the need for high-risk formwork, scaffolding and wet trades in a confined working environment.
In addition to the lift shafts, Ibstock also supplied precast stair units to the site. These were successfully installed by the steelwork subcontractor, Ballard Engineering Ltd, further streamlining the build process and reducing onsite construction time.
By manufacturing the key structural elements offsite, Ibstock was able to provide a flexible and responsive solution aligned to the tight programme constraints. The project highlights how precast concrete can offer a reliable, high-quality alternative to in-situ construction, particularly in healthcare environments where speed, safety and precision are paramount.