In total Willerby Innovations completed 122 unique single storey lodges at the Enchanted Village Alton Towers. Despite the unusual roof design necessitating 5 pitch changes, Willerby designed a modular solution which enabled the roofs to be manufactured and tiled in the factory, requiring a simple connection, providing significant programme benefits and enabling earlier letting.
Undertaken for Merlin Entertainment, The Enchanted Village comprises of two bedroom and bathroom accommodation designed to evoke a fairy tale experience. Small porthole windows, rough timber cladding, rough timber circular glazed entrance and inset doors, and crooked pantiled roofs and chimneys all help to enhance the experience.
To enable this bespoke design to be manufactured to a tight budget and a demanding timescale, Willerby Innovations team of designers created a modular solution incorporating efficiencies and manufacturing excellence normally associated with the most sophisticated engineering plants.
In order to further enhance the programme, the manufacturing facility was re-engineered to accommodate ‘just in time’ manufacture of the ‘crooked’ roofs, which required 4 pitch changes and joists, the incorporation of pantiles and a crooked chimney.
Internally the factory line accommodated the inclusion of specialist joinery, the incorporation of bathrooms, bespoke themed flooring, flat screen TVs and bunk beds for the children.
Externally the modules were factory rendered and delivered to site where modules were joined in pairs and the roof modules stitched together in-situ for maximum programme efficiencies. In all the 122 units were manufactured at a rate of one every four hours and installed on site in just two weeks, providing programme and quality benefits unachievable with traditional build.