Darwin Group® | On-Demand Ultraclean Operating Theatres®

This case study explores Raybloc’s collaboration with Darwin Group® to deliver integrated radiation shielding solutions for On-Demand Ultraclean Operating Theatre® facilities. The project combined Raybloc’s specialist shielding expertise with The On-Demand Ultraclean Operating Theatre® by Darwin Group® to support high-acuity surgical environments requiring strict infection control, radiation protection, and structural precision.

From early technical coordination through to manufacture, phased delivery, and installation, this project demonstrates how close collaboration between Raybloc, using its unique PVC-encapsulated rebated stiles, and specialist healthcare designers can result in safe, compliant, and operationally robust healthcare infrastructure.

The Challenge

The On-Demand Ultraclean Operating Theatre® by Darwin Group® is designed to provide permanent-grade surgical capacity in a hireable, modular format. These facilities are intended for complex surgical disciplines such as orthopaedics, cardiothoracic, neurosurgery, and other high-risk procedures requiring the highest standards of environmental control, structural integrity, and regulatory compliance.

As part of this programme, Darwin Group® required radiation shielding solutions that could integrate seamlessly into:

• Solid concrete-floored theatres
• Ultra-clean ventilation environments
• Modular structures intended for rapid deployment and adaptability

Unlike conventional hospital refurbishments, the challenge lay in ensuring that shielding performance, hygiene standards, fire strategy, and structural detailing could all be achieved without compromising the modular, adaptable nature of the theatre units.

A further challenge related to automation and infection control. In hygienic theatre environments, standard finger guards are not suitable due to their potential to harbour contaminants. This required an alternative approach to door safety, leading to the use of flat scan sensors to maintain safe operation while adhering to strict infection control standards.

Installation of Customised Radiation Protection Solutions

Raybloc’s engineering and installation teams worked in close coordination with Darwin Group® throughout the programme, ensuring shielding, automation, and architectural detailing were aligned with modular construction sequencing, hygiene protocols, and regulatory requirements. This integrated approach ensured that radiation protection, operational flow, and infection control were delivered as a unified system rather than a series of isolated components.

The Solution

Raybloc collaborated closely with Darwin Group® technical and project teams to specify, manufacture, and install a comprehensive shielding package across multiple theatre units.

The scope included: 

• Lead lined wall panels using 15mm Knauf Performance Plus plasterboard with Code 4 (1.80 mm Pb) lead equivalence
• A range of unique bespoke PVC encapsulated (rebated meeting stile) lead lined doorsets, including single, double, and unequal leaf configurations
• Flush-mounted vision panels with laser blackout interstitial blinds
• Integrated Raybloc flush mounted LED two-stage warning lights
• Heavy duty automatic door operators for high-use clinical flow
• Full installation and reinstallation services aligned with phased construction logistics

All components were manufactured in-house by Raybloc and installed by Raybloc’s specialist team to ensure continuity of responsibility, performance assurance, and compliance.

Specifications and Requirements

Wall Shielding

• Raybloc® Panels 15mm Knauf Performance Plus Plasterboard
• Lead Equivalence: Code 4 (1.80 mm Pb)
• Complete with 3000 mm × 50 mm lead strips

Doorsets

• Raybloc® Double Doorsets (rebated meeting stile, PVC encapsulated)
• Raybloc® Single Doorsets (PVC encapsulated)
• Raybloc® Unequal Doorsets (astragal meeting stile)

All doorsets supplied pre-hung with:

• Code 4 (1.80 mm Pb) lead equivalence
• Flush-fit laser blackout interstitial blinds
• Stainless steel kick plates
• Heavy-duty lift-off hinges
• Raybloc® flush-mounted two-stage LED warning lights

Automation

• ED250A automatic operators on selected doors
• Full energy operation with safety sensors and radar activation

Compliance & Assurance

• Designed and supplied in line with IRR17 and RPA requirements
• 10-year material and workmanship guarantee
• 10-year radiation shielding warranty on Raybloc-installed products

The Benefits of Installing Control Booths, Windows and Doorsets from Raybloc

This project highlights the value of early technical alignment between specialist healthcare designers and us.

By integrating shielding into the modular theatre design of Darwin Group® at an early stage, the project achieved:

• Seamless radiation protection without disrupting modular construction logic
• Clean, flush finishes aligned with ultra-clean ventilation and hygiene requirements
• Structural reliability within lightweight modular assemblies
• Smooth patient and staff flow via automated heavy-duty doors
• Long-term durability suited to high-intensity surgical environments

It also reinforced a trusted partnership between Raybloc and Darwin Group®, built on technical transparency, collaborative problem-solving, and shared commitment to patient safety and operational excellence.

About Raybloc Radiation Protective Products

Raybloc is a leading UK manufacturer of radiation shielding systems for healthcare, research, and industrial environments. From lead-lined doors and windows to wall panels and bespoke solutions, Raybloc designs, manufactures, tests, and installs all shielding products in-house.

With more than 25 years of experience, Raybloc specialises in translating complex radiation protection requirements into compliant, durable, and architecturally integrated solutions.

Together, Darwin Group® and Raybloc demonstrate how engineering, architecture, and physics can align to create safer, more adaptable healthcare environments for the future.