Rosyth New Build Hall

Featuring two MegaDoors and internal gantry cranes, the facility will become only the second hall of its kind at Rosyth, building on the success of the Venturer Assembly Hall.

Drawing on its experience from the Venturer project, Careys was appointed by Robertson Construction to support the scheme from the outset through Early Contractor Involvement (ECI). Working collaboratively with Robertson, Babcock and the wider project team, Careys has helped shape the enabling works design and delivery strategy, focusing on buildability, logistics, programme optimisation, risk management and stakeholder engagement.

One of the project's most significant challenges has been achieving the precise alignment of the new facility with the existing Venturer Assembly Hall. With minimal tolerance for deviation, this alignment is critical to maintaining a direct route to the basin and ensuring the efficient movement of large ship modules and vessels. Early risk identification and collaborative design reviews have helped de-risk the scheme and inform the overall construction strategy.

Construction commenced in late 2025 with enabling works, including 14,000m³ of cut and fill operations, service diversions and a 6,000m³ piling mat. Careys is now delivering the main civil engineering works, including pile cap foundations, drainage infrastructure and preparations for 13,500m² of reinforced concrete slab construction. In total, the works will incorporate 3,780 cropped piles, 6,750m³ of concrete and 850 tonnes of reinforcement.

Operating within an active naval dockyard presents additional complexities, from stringent MOD security requirements and challenging historic ground conditions to demanding quality standards and logistics constraints. To address these challenges, Careys has implemented robust planning, dedicated security management and collaborative delivery processes.

The project also incorporates a low-carbon concrete solution containing up to 60% GGBS, reducing embodied carbon while meeting the durability and performance requirements of a modern shipbuilding facility. Scheduled for completion in 2027, the New Build Hall will play a key role in strengthening Rosyth's shipbuilding capabilities for decades to come.