Plasterboard and wall insulation had to be removed from a new hospital project in Aberdeen because of mould and water ingress.
The Baird and Anchor Centre are still under construction, years overdue, and hundreds of millions of pounds over the original budget.
An internal document in 2023, seen by STV News, shows mould growing on plasterboard which had already been fitted.
An infection control team observed water ingress “into insulation and plasterboard around most of the perimeter walls”.
It also said other materials had been stored in the buildings before it was weather-tight.
The recommendation was for all dry fittings, including the plasterboard and insulation, which had been exposed to water and showing signs of mould growth, to be removed and replaced.
The experts warned that construction material which had been wet or previously wet would pose a health hazard for the lifetime of the material being in the building.
The new Baird Family Hospital will replace the current maternity hospital, while the Anchor Centre will care for cancer patients.
Areas impacted included the new Neonatal Unit, theatre suites, and consultation rooms at the Baird hospital.
The issue of mould growth at the two sites was revealed to the board of NHS Grampian in 2023.
At the time, it also raised several issues around the building of the two sites.
This included about air changes at the Anchor Centre, and a terrace at the centre would have allowed a mix of natural and mechanical air, meaning contaminated air could have entered the building where patients were being treated.
Problems with the water system at the Anchor Centre were also raised.
The document from experts also warned that mould growth can happen between layers of plasterboard and that, after testing, it was found that Penicillium chrysogenum was the most common species discovered.
In one instance, inspectors said they had found someone had tried to remove the mould, but traces were still found.
Graham, who are the main contractors for the development, have been contacted for comment.
NHS Grampian director of infrastructure, sustainability and support services, Alan Wilson, said: “I fully understand concerns raised about water ingress within the Baird and ANCHOR Projects, but would like to offer assurance that work has been undertaken to identify and repair any areas affected.
“Water ingress and mould growth were publicly reported to our board in late 2023, following concerns from our Infection Prevention and Control Team (IPCT).
“At that stage, we shared a report with NHS Assure for advice on the most effective method of providing assurance in this area. At the same time, the project team actively progressed additional testing and sampling in areas adjacent to known instances of water ingress.
“As later reported publicly to the board in 2025, remediation measures were carried out by the contractor, and, after completion of additional works, additional monitoring will be undertaken by the contractor during the functional commissioning stages and in the early periods of occupancy.
“Our IPCT has been part of a group of stakeholders – including an external expert Dr Malcolm Richardson, of the University of Manchester, a leading clinical mycologist with experience of mould development in healthcare settings – that helped instruct works following the water ingress.
“The ANCHOR Centre and Baird Family Hospitals will not open without a supported NHS Scotland Assure Key Stage Assurance Reviews (KSAR) status. KSARs provide independent assurance that major NHS construction and refurbishment projects are being planned, designed, and delivered safely – with a focus on infection prevention and control (IPC) and technical compliance.”
The latest revelations come after STV News revealed concerns by a whistleblower that the new hospital projects were “downplayed” with public money being “wasted”.
An investigation found that a key process in the design of the new project was not carried out, leading to concerns over infection risks, redesigns and rising costs.
NHS Grampian at the time said it welcomed the conclusions and recommendations of the independent third-party investigation.
It found that a risk assessment system known as HAI Scribe (Healthcare Associated Infection System for Controlling Risk in the Built Environment) wasn’t properly completed during the design of the Baird and Anchor.
It also found that in the early years of the project, concerns were raised but “were consistently downplayed, and there remain individuals who continue to minimise infection prevention risks.”
The Baird Family Hospital and Anchor Centre were originally due to open in 2020 and cost around £134 million.
Neither site has opened yet, and the current budget is around £438m.
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