Chester Zoo Heart of Africa

The site sits within one of the country's most-visited tourist attractions, home to a vast collection of animals that react to any change in their surroundings. Cranes could not be used without careful planning — any change to the skyline can distress many species — drones were effectively ruled out, and construction noise had to be managed thoughtfully to avoid alarming the animals or spoiling the visitor experience. Though separate from the Zoo, the site was visible from within it and reached via the main visitor access road, so deliveries and the working entrance had to be managed around peak visitor flows at all times.

Individual species brought their own demands — the giraffe house had to be kept at an ambient 18°C with a five-metre door — while the client's ambition to reach Net Zero by 2030, and the need to take an existing pumping station out of commission and replace it with minimal disruption, both shaped the works.

Collaboration was built into the contract from the outset. A dedicated pre-construction design manager met the client fortnightly and was in daily dialogue for 12 months, with design and information flow managed through Builderstorm and weekly liaison meetings held with the client and each animal team. On site, biometric face-recognition turnstiles controlled access and induction, deliveries were sequenced to protect the visitor experience, and 30% of the workforce was McPhillips' own directly employed staff, all trained to work sensitively within a live zoo.

Sustainability ran throughout: air source heat pumps and PV panels where suitable, demolition materials recycled on site, the earthworks model adjusted to minimise off-site disposal, and existing wood and trees reused within the enclosures. Where a heat pump could not keep the giraffe house warm enough, a highly efficient low-emission gas solution was used instead, while bespoke retaining-wall designs and value-engineered finishes, lighting and even the savannah sand identified around £3 million of savings.

Heart of Africa has been delivered on time and on budget, with around £3 million of value-engineering savings and zero working hours lost to accidents. Close partnership with the Zoo enabled the early, non-contractual handover of the 10-metre-tall giraffe house so the animals could move into their new home in warmer weather.

The project also reflects McPhillips' commitment to local supply chains — the largest single sub-contractor, covering 10% of the project value, is based within ten miles of the Zoo, the savannah rocks were sourced from local quarries, and 92% of the 220-strong workforce is based within 20 miles of the Telford headquarters.