Case Study: Handcrafting a 5.7m x 3.2m Bespoke Acoustic Timber Enclosure for DoubleTree by Hilton Cheltenham-Cotswolds

Project Quick Facts (At a Glance)

1. The Client Brief: Soundproofing a CHP Generator at a Luxury Hotel Resort

When main contractor Avrenim Group and Emerald Builders were tasked with installing a new Combined Heat and Power (CHP) generator unit at the prestigious DoubleTree by Hilton Cheltenham-Cotswolds, they faced a complex engineering and operational challenge.

CHP engines generate significant mechanical noise and heat. Because the generator sits directly on site near guest accommodation overlooking the hotel resort and spa, placing an unshielded industrial unit outdoors was impossible.

The project demanded a custom acoustic timber enclosure that could:

1. Dampen High-Decibel Acoustic Output: Eliminate sound transfer to nearby guest rooms while maintaining adequate airflow for engine cooling.

2. Mount Directly to Concrete Padstone: Anchor securely onto an existing 250mm thick concrete plinth (5.7m x 3.2m) without requiring an integrated timber floor.

3. Integrate Specialist Acoustic Louvres: Accommodate heavy steel Allaway AL1515 acoustic ventilation louvres built into the wall framing.

4. Provide Full Maintenance Access: Feature wide 2.1mm tall double doors for engineers to service the CHP engine comfortably.

Arbor Garden Solutions was selected to design, pre-fabricate, deliver, and install the complete acoustic housing on site.

2. The Fabrication Process: From Wisbech Workshop to Final Build

To achieve maximum noise reduction while ensuring weather resistance and ventilation, our Wisbech-based carpentry team executed a meticulous manufacturing workflow:

• Foundation & Framing: Fabrication commenced by laying a 3x2 pressure-treated timber perimeter ring over a sill sealer moisture barrier, establishing a solid, damp-proof foundation. We then erected the pre-assembled 3x2 kiln-dried timber wall frames to form the central structural shell.

• Roof Assembly: 6x2 timber rafters were fitted and decked with oriented strand board (OSB) to create the heavy-duty roof assembly. The external architectural finish was achieved by installing corrugated bitumen roof panels over a 35x25mm batten grid.

• Thermal & Acoustic Core: The internal cavity was thermally and acoustically optimized by securing 40mm PIR insulation boards across the framing, finishing the interior surfaces with durable 9mm green MDF panels.

• Weatherproofing & Exterior Cladding: The complete exterior structure was wrapped in an Onduline breathable membrane and vertically battened to ensure proper ventilation and moisture runoff. Finally, we secured horizontal tongue and groove timber cladding directly to the exterior wall battens.

• Hardware & Louvre Integration: The workflow was finalized by hanging heavy-duty timber double access doors on galvanized strap hinges. The heavy steel acoustic ventilation louvres were then precision-framed with matching exterior tongue and groove trim to complete the robust structural integration.

📷 Workshop & Engineering Process Gallery

CAD drawings and manufacturing process of the bespoke acoustic CHP generator enclosure in Wisbech workshop.

3. On-Site Installation: Navigating Strict Hotel Noise Restrictions

Installing a large timber commercial structure at a 4-star hotel running at 96% guest capacity presented unique logistical constraints:

• Restricted Working Windows: To preserve the quiet luxury atmosphere for hotel and spa guests, the hotel management imposed strict operational rules: no work before 8:00 AM, strictly NO noisy power tools before 9:00 AM, and all work wrapped up by 6:00 PM.

• Agile Scheduling: When delivery of the main CHP engine was delayed in transit, our project coordination team seamlessly rescheduled delivery and fitting dates to August 4th to align with the revised main contractor timeline.

• White-Glove Installation: Our specialist fitting crew carried out silent framing prep early in the mornings, concentrating battery-operated impact driving and panel assembly into the approved midday hours. The complete acoustic structure was erected, insulated, lined, and sealed on site on schedule.

Despite the challenges, the complete acoustic structure was erected, insulated, lined, and sealed on site with precision.  

🎥 See the Finished Project On-Site:

4. Commercial & Utility Timber Solutions by Arbor Garden Solutions

The completion of the DoubleTree by Hilton Cheltenham CHP enclosure highlights our capability in commercial, industrial, and high-spec utility timber construction. From plant rooms and generator housings to acoustic screening and modular utility compounds, we deliver bespoke UK-built structures tailored to your exact site requirements.

Why Commercial Clients Choose Arbor Garden Solutions:

• 100% Handcrafted in Britain: Manufactured in our Fenland workshop in Wisbech, Cambridgeshire.

• Full End-to-End Service: CAD schematics, technical advice, pre-fabrication, UK-wide delivery, and professional on-site installation.

• Specialist Material Integration: Experts in soundproof PIR insulation, fire/moisture-resistant linings, acoustic louvres, and heavy-duty roofing.

Need a Custom Utility Enclosure or Commercial Plant Housing?

Whether you require acoustic plant housing, commercial refuse enclosures, custom workshops, or bespoke garden buildings, our technical team is ready to assist.

👉 Explore Our Commercial Modular Enclosures Range

👉 Submit a Bespoke Commercial Enquiry

📞 Call Our Technical Sales Team: 01945 410950