MMC 5543 48 May '16 cc (1)

Factory installed fire protection
MMC Magazine examines the potential of a proven firestopping
product range.
MODERN METHODS OF CONSTRUCTION
> issue 5543 | May | 2016
Cold-roll renaissance
Technical Editor Bruce Meechan visits Britain's
traditional ‘metal-bashing’ heartland to discover how
one company is giving steel framing a very modern ring.
Timber driving its own design agenda
Technical Editor for MMC, Bruce Meechan, attends an
evening seminar in the capital which brought together
some eminent advocates of wood as a material for
major buildings.

A W A R D W I N N I N G L E D L I G H T I N G S O L U T I O N S
Specialising in
LED lighting for
modular projects
Lighting Manufacturer of the Year, 2015
projects@auroralighting.com 01793 467 200
auroralighting.com

CONTENTS
Dear Readers
I have a question for stockbrokers, or any of you who
might dabble in shares: if the country votes for Brexit on
June 23rd, will Nigel Farage insist on deporting his
German born wife? Ridiculous idea of course, but not
much dafter than the theories which have seen the value
of our major housebuilders’ yo-yoing over recent weeks,
in response to the varying opinion polls.
The ‘logic’ goes like this: if we vote to Leave not only will
immigration fall - cutting demand for new homes - but
there will be no Eastern European tradesmen to build
them. The facts are that we haven’t been building enough
homes since before the Barker Report and recession, and
it will take decades to catch up with demand whatever
happens in the referendum. Meanwhile virtually everyone
backing Brexit also favours a Green Card scheme so we
can still admit the skilled workers our economy needs.
I therefore sincerely believe the vote next month will have
little impact on developers, nor therefore the demand for
the various products and materials they consume.
Beyond the bank dealing floors, the latest figures for
activity in the sector are very positive, with Barbour
reporting construction contracts were up by 10 per cent
in March to over £6 Billion. And of that, residential work
accounted for a surging 31%. Commercial and retail were
also doing very well and I know from manufacturers
serving the education sector that they are gearing up for
the annual summer surge in school building; as well as
the continuing clamour for more accommodation and
other facilities across our ever expanding college
campuses.
Furthermore, this demand led activity is creating an
increasingly positive environment for those providing
offsite solutions; particularly for residential work where
both regulation and the required speed of build are
pushing developers to adopt modern methods of working.
Which will, by the way, also help reduce reliance on
traditional trades. So rather than sell my shares in UK
housebuilders I intend to buy some more and sit on them
until The City finally gets over its jitters.
I am also confident that you will find the contents to this
May issue of MMC an interesting reflection on the activity
and opinions across one of the UK’s most vibrant business
sectors.
Yours sincerely
Bruce Meechan
Editorial Enquiries Tel: 01827 301190
Press Releases, Advertising, Production,
Design & Circulation Enquiries
Tel: 01827 301198
Features Editor Bruce Meechan
News Editor Juliet Woodcock
Press Co-ordinator Gemma Spilsbury
press@wavcoms.co.uk
Advertising Nasser Agha-Khan
mmc@wavcoms.co.uk
Design Ellie Rich and Di Smith
Circulation
circulation@wavcoms.co.uk
Publisher’s Statement
MMC is published quarterly. Although the editor and publisher
make every effort to return photographic material, it is sent at
owner’s risk. Printed in England. All rights reserved. No part of
MMC may be reproduced or stored in a retrieval system or
transmitted in any form without prior permission of the editor.
Whilst every effort is made to ensure the accuracy of editorial
content, the editor and publishers do not accept responsibility for
errors or loss and damage caused by any statements, claims or
observations made by contributors, authors and their agents.
Waverley Communications Ltd.
Waverley House, 11 Galena Close,
Amington Heights, Amington Industrial Estate,
Tamworth, Staffordshire. B77 4AS.
12 Timber now growing on
developers
Andrew Carpenter, Chief Executive of the STA,
offers MMC’s readers an insight into the health
and ambitions of the structural timber industry.
18 WDH - Awake to the benefits of
building offsite
Building infrastructure in the UK is under
review once again – the recently created
National Infrastructure Commission is due to
deliver its first report shortly – and better
insulation of homes is one of the areas it could
address as a part of its wider remit.
42 G-frame engineered timber &
hybrid structures
G-frame Structures specialises in the design,
supply and installation of engineered timber
and hybrid structures. A designer of bespoke
solutions, G-frame Structures offers a direct
route to a complete hybrid package.
47 Shackerley cladding is right on
track at Newbury Racecourse
Ventilated façade specialist Shackerley has
supplied over 3000m 2 of white SureClad ®
ceramic granite cladding for three luxurious
apartment complexes at one of the UK’s
premier racecourses.
issue 5543 | May | 2016
20 Triple timber solution to
sustainability
Technical Editor Bruce Meechan looks at the
range of very low carbon solutions available
from a major timber frame manufacturer based
on the Shropshire - Mid Wales border.
40 Optima from Profile 22: futureproof
high performance windows
Months of rumours and speculation are now at
an end as Profile 22 launches not one but two
of the industry’s most eagerly awaited window
and door systems.
< Front cover
Our new OPTIMA range represents the
latest innovation in windows and doors.
It promises the best thermal
performance for today and the future,
with 4 new systems - two complete main
profile systems and two brand new niche
window systems.
See page 40 for more info...
www.profile22.co.uk
MMC May 2016 3

NEWS
£700m construction
cost for world's tallest
tower
The building set to become the
world’s tallest, when it is completed
in 2021, will cost £700m to build.
Developer Emaar Properties announced
the price tag for the Dubai Creek Harbour
Tower at a London event in April, held with
Knightsbridge agents Harrods Estates, to
market apartments in the wider
development.
Construction work is planned to start in
July and will take four years to complete.
Google inspires new BIM app platform
ABristol-based start-up hopes that its new platform for BIM apps – now available in
Beta at jenca.org – will mark the arrival of today’s modern web technology in the
BIM world, offering industry professionals the user-friendly, intuitive interface
associated with Google apps.
Users will be able to launch different BIM apps from within the cloud-based Jenca
platform, in the same way as Google users can launch YouTube, Google Play or Gmail or
other apps once they’re logged in to Google’s domain.
The free-to-use platform will host applications from third-party software vendors and
independent software developers. Currently, users can access apps from Owncloud,
Redmine, Rocketchat, Ghost, Flarum and others.
The platform is based on open-source code called Kubernetes, an equivalent of the “Borg”
technology that Google uses to run its data centres.
According to Jenca, this means that the Jenca platform can run BIM applications at data
centre scale, confirming it will be able to cope with the massive volumes of data that will
be in use as the industry moves towards Level 3 BIM.
A final decision on the height has not yet
been made, though it will be at least 832m
high. This will ensure it tops the nearby
Burj Khalifa, 828m high, currently the
world’s tallest building.
The tower has been designed by Spanish
architect Santiago Calatrava and will form
a focus for the Dubai Creek Harbour
project.
It will contain a boutique hotel, and the
upper 20 floors will comprise shops,
restaurants, function rooms and
observation decks, with a rotating balcony
at the top.
The building that
'sucks up' smog
An Italian construction firm has
developed a 'biodynamic' mortar
that is able to remove pollutants
from the air automatically.
The mortar, which is made from recycled
scraps of marble and left over aggregate,
absorbs nitrogen oxide and sulphurous
pollution, converting it into harmless
salts.
It uses a titanium catalyst that is
activated by ultraviolet light to drive the
chemical reaction. The salts then wash
off the walls when it rains.
It has already been used to create a
building in Milan called the Palazzo Italia,
which was completed for the World Fair in
the city in 2015.
RIBA Exhibition: Designing the House of
Tomorrow (18 May – 29 August 2016)
The Architecture Gallery, RIBA (Entrance is free)
At Home in Britain: Designing the House of Tomorrow re- examines how we live and
showcases thought-provoking ideas for future housing design. Taking the cottage,
terrace and flat as starting points, six contemporary architecture practices from
Britain, the Netherlands and France have been commissioned to transform the three
familiar typologies to reflect the way we live and work in the 21st century.
Using material from the RIBA Collections as stimuli, the architects will celebrate and
critique vernacular housing of the past and explore ideas of affordability, communal living
and housing density today. The new work will be displayed alongside photographs, books
and drawings from the collections.
CITB and HBF: major new partnership to tackle
housing skill needs
Over 45,000 new homebuilding workers will be trained by 2019 to help tackle the
nation’s housing shortage through a £2.7 million initiative announced today by
the Construction Industry Training Board (CITB) and Home Builders Federation
(HBF).
The first of its kind, the Home Building Skills Partnership – working with research on their
needs from some 40 UK home builders - will bring together firms of all sizes to ensure that
the industry has the tradespeople and specialist installers it needs to build more homes.
This will include initiatives to promote collaboration on skills across the supply chain, so
that the industry can better plan for its future needs.
The partnership will support over 3,500 construction businesses and, by 2019, train
45,000 new entrants and 1,000 experienced workers with the new homebuilding training
qualifications. This new partnership will use industry insight to understand skills needs and
develop new training and qualifications ideally suited to the modern homebuilding sector.
It will create long-term solutions to meet the government’s target of one million new
homes by 2020.
4

Scientists create
transparent wood
Glass windows may soon be a thing
of the past.
Researchers from KTH Royal Institute of
Technology in Stockholm have developed a
transparent wood material that could
change the way we construct buildings and
solar panels.
The new material is suitable for mass
production, the researchers say, and is a
low-cost renewable resource.
If used in the construction of homes and
other buildings, a transparent wood
material has potential to improve indoor
lighting, allowing natural light in through
the walls.
This could save on the costs of artificial
lighting, and may even have use in solar
cell windows.
Cyber crime costing
construction firms
£1.8bn a year
Cyber crime and the manipulation of
fake invoices are costing the UK
construction industry more than
£1.8bn every year.
Cyber crime is one of the biggest-growing
concerns for the construction industry,
especially as it moves into embracing BIM
and more work is going online, as was
reported and explored in depth by CM in its
recent feature BIM and Cyber Security:
Defending the Chain.
The research carried out by Tungsten
Network found that from construction
companies surveyed, 60% have received a
fraudulent or suspicious invoice in the last
year – this is significantly more than any
other sector and the national average of
47%.
Tactics have included: viruses embedded in
attachments; unknown invoices attached to
an email or sent by post; false changes to
bank details and sending duplicate invoices.
The research also revealed that worryingly,
not every company is aware of the high
stakes – 11% of construction businesses
would take no action if they received a
suspicious invoice and 6% wouldn’t know
what to do.
Only around half (54%) would contact the
police or a reporting service like Action
Fraud, showing that there is still an
education job to do in terms of knowing
how to handle cyber-crime.
Planning approvals for new homes at highest
since 2008, says HBF
Planning permissions for new homes are at their highest since 2008, according to
the Home Builders Federation (HBF), but many still face significant hurdles before
construction can get underway.
Initial planning permission for 255,032 new homes was granted in England in 2015 – up 57
per cent from a low point of 162,204 in 2009 – according to HBF and Glenigan’s latest
Housing Pipeline report.
Permissions granted in the fourth quarter of 2015 were up 13 per cent on the same
quarter in 2014, to 74,759, as developers submitted more applications to deliver further
increases in supply.
Furthermore, permissions have risen steadily every year since 2009, with actual housing
supply also increasingly “markedly” over the past two years. This latter rise has come
about as more of the permissions are progressed to the point that infrastructure work
can start and house builders can begin building new dwellings, the report says.
Over 180,000 new homes were added to the housing stock in 2014/15 – up 22 per cent on
the previous year.
However, despite the rises, many of the permissions counted in the report still have
“many hurdles” to cross as they “navigate the complexities of the planning system”
before actual building work can get underway – for example discharging planning
conditions.
As a result, the HBF said the industry is continuing to urge Government to streamline the
planning process and ensure local authorities have the capacity to deal with the volume
of applications now being processed so builders can get on to more sites more quickly.
Low and zero carbon homes threatened by
Government policies, report finds
The Government’s ability to meet EU targets for delivering low carbon homes following
the Paris international climate change agreement has been challenged by a new
report. The report entitled ‘Future of policy and standards for low and zero carbon
homes’, by academics from the University of Westminster and the University of Hertfordshire,
highlights the serious implications of Government policy changes and the scrapped plans to
make all new homes carbon neutral from 2016.
The publication of the report comes at the same time as news of the forthcoming closure of
the Zero Carbon Hub following loss of funding. Set up in 2008, the Government and industryfunded
Zero Carbon Hub had been focusing on improving building standards and reducing the
risk associated with implementing the Zero Carbon Homes policy.
Funded by the Royal Institution of Chartered Surveyors, the ‘Future of policy and standards
for low and zero carbon homes’ report evaluates policy and standards for promoting the
delivery of low and zero carbon homes in England in the context of the 2012 Housing
Standards Review and the withdrawal of the zero carbon target.
Chinese sea container firm to build Hilton hotels
AChinese shipping containers company has agreed a “strategic partnership” with hotels
chain Hilton to develop a series of modular hotels in the UK and globally.
China International Marine Containers (CIMC), which made its name producing shipping
containers and recently moved into modular buildings, is currently constructing a 201-bedroom
hotel for Hilton Worldwide at Bristol Airport.
The scheme is financed and will be owned by CIMC, and managed by Hilton.
A spokesperson for the Chinese company said: “CIMC’s innovative modular technique
significantly reduces the time taken for construction by manufacturing and assembling sections
of the hotel, including guest rooms and hallways, in China, before transporting them to the final
site for assembly. The model helps ensure consistent quality and accelerates the build schedule
on site, a benefit for developers and investors in mature and emerging markets alike.”
MMC May 2016 5

Product News >
MVHR made easy
with Posi-Joist
The Posi-Joist floor system was
recently used on high quality homes
for Severnside Housing, incorporating
the latest in Mechanical Ventilation
and Heat Recovery systems.
Severnside Housing is one of
Shropshire’s largest social landlords
owning more than 5,400 properties in
Shrewsbury and the surrounding
areas. A not-for-profit company, they
invest to deliver their vision of
‘Excellent Homes in thriving
communities.’ Morris Property Ltd
were chosen by Severnside due to
their reputation for building high
quality homes and the long standing
relationship between the companies.
Spray-applied plasters make light work of TV
superhome
Fairways, the Isle of Wight superhome showcased in September’s Grand Designs programme,
involved plastering 7,500ft2 of concrete, blockwork and plasterboard to a tight schedule, and
features large areas of impeccable plastering made possible by spray-applied MP75 Readymix
Plaster from Knauf – one of the UK’s leading manufacturer of lightweight building materials
and systems.
The principal product applied at Fairways was Knauf MP75 Projection Plaster, a one-coat
plaster that provides a tough and durable smooth white surface ready to receive decoration.
Delivered to site pre-mixed ready to use and specifically designed for machine application,
Knauf MP75 offers excellent productivity and is up to three times faster than traditional
plastering methods.
Elliott wins £30m EFA contract
Elliott, part of the Algeco Scotsman Group, world
leader in modular space solutions, has been awarded a
contract of over £30m by the Education Funding
Agency (EFA). Elliott will serve as the main contractor
in the PSBP Modular Primary Schools procurement
scheme and will be responsible for building up to ten
new schools to accommodate around 3,000 pupils
across Southern England. As part of the scheme Elliott
will be responsible for building a new school on each of
the existing sites using a modular construction
solution.
It can be applied up to 20mm thick in one
application and is suitable for use directly onto
blockwork, uneven in-situ concrete or thin joint
blockwork. The plasters dry rapidly and are easy
to finish – just spray, level, sand and paint.
www.knauf.co.uk
“With the Elliott Hybrid and Ibex construction solutions we can reduce the build programme
considerably, allowing each of the schools to take a much earlier occupation of their new
building than if they were using traditional methods of construction,” said CEO of Elliott, Lee
Jon Newman.
Elliott has over 50 years experience of providing permanent and temporary building solutions
with a strong reputation in the education sector.
www.elliottuk.com
Vortice demonstrates
response to ErP directive
AC Roof Trusses were chosen by
Morris Property to supply and install
the timber frame walls, roof trusses
and Posi floor joists for the 28 room,
three-floor apartment block. The
apartments are to have a robust detail
sound floor along with a MVHR system
in each of the apartments. The two
bedroom apartments all have ‘state of
the art’ MVHR systems supplied and
installed by SCS Group (Shropshire
Cooling Services).
www.mitek.co.uk
With the ErP directive setting minimum
performance criteria for ventilation becoming
effective from 1st January 2016, Vortice has
reviewed and responded to these changes. The
ErP directive, which is European legislation,
applies to products which can have an effect on energy consumption throughout their lifecycle,
from manufacture, through use, and until the end of their life.
With ventilation systems falling under this category, Vortice has set out changes within many
of its fan ranges to ensure all products are fully ErP compliant. Products that fall within ErP
also now have to carry an energy efficiency class rating which gives information about the
energy efficiency of the product.
“It is important that, as a large manufacturer, Vortice responds to these changes swiftly and
effectively,” explained Kevin Hippey, Vortice General Manager. “As an energy conscious
company we want to ensure all our products meet these new energy efficient regulations.”
.
www.vortice.ltd.uk
6

Product News >
School wins race
against time
The Kingspan TEK Building System of
structural insulated panels has been
installed as part of a modern, energy
efficient classroom block at Boyle and
Petyt Primary School in the Yorkshire
Dales, helping the school to meet its
strict funding deadline with a nine-day
erection programme. Kingspan TEK
Delivery Partners, SIPS@Clays LLP,
helped to ensure that was achieved by
designing, fabricating and fitting the
Kingspan TEK Building System to form
the roof and walls of the block.
The Portakabin Group achieves UK construction
industry first
The Portakabin Group has been awarded the £14m design and build contract for the UK’s first
university technical college (UTC) to be built off site. The Global Academy will provide
academic and vocational training for 14-19 year olds who want to work in the broadcast and
digital media industries. Designed by the Portakabin Group and architects Surface to Air, the
building has a forward-thinking, innovative design to reflect the creative ethos of the new
Global Academy.
Advanced off-site technology using a Yorkon building solution from the Portakabin Group will
seamlessly integrate both modular and site-based construction. A significant proportion of
the work will be completed off site at the
Portakabin Group factory in York in order
to meet the challenging programme for
completion in time for the start of the
2016-17 academic year.
The technically-complex building is also
designed to deliver a demanding acoustic
specification for the broadcast studios,
with triple glazing and speciallyengineered
air conditioning.
www.yorkon.info
Make the connection
Leading construction connector manufacturer
Simpson Strong-Tie has developed a range of
structural screws aimed squarely at the engineered
timber construction industry.
Available in lengths up to 400mm, the ETA
approved range includes washer head and
countersunk options suitable for all manner of
timber construction technologies including timber
frame, CLT, SIP and Glulam as well as being an
excellent method for joining multiple I-joists or trusses to act as a single member – all without
pre-drilling.
“Easy and fast to install, these screws offer high tensile capacities and superb pull-out
resistance,” explained Simpson Strong-Tie Sales Director, Jon Head.
www.strongtie.co.ukw
Kingspan TEK Building System panels
incorporate a fibre-free insulation core
sandwiched between two layers of
OSB/3. The panels are pre-cut to each
project’s specification, limiting on-site
alterations. This bespoke approach,
combined with the panelised system of
construction, helped to ensure a fast
and predictable installation
programme. SIPS@Clays LLP began
site work on the 15th of December and
completed the erection in time for
Christmas. With the SIPS@Clays
factory also being located near the
school, this ensured transport mileage
was kept to a minimum.
www.kingspantek.co.uk.
Maintaining the
Victorian aesthetic at
Alvaston Hall
When it came to expanding the beautiful
Alvaston Hall Hotel in Cheshire, maintaining
the attractive Victorian aesthetic of the
original building was a top priority, and
Warner Leisure Hotels needed a materials
provider to match the scale and ambitions
of their £12m expansion. To match the style of the older buildings, Redland’s Plain Tile, a
concrete tile with a traditional plain tile appearance was used, in ‘Breckland Black.’ These slate
grey tiles are finished with a red-tinged streaking effect to simulate the look of a weathered
roof, ideal to mimic the look of the original Victorian building.
Redland is able to liaise with roofing contractors on jobs of all sizes to provide flexibility in
providing materials and assistance on site for clients. In this case, tiles were sent directly to
site following a scheduled programme of deliveries, helping contactors to cope with the huge
numbers of tiles needed to complete work on the hotel.
8
www.redland.co.uk/plaintilew

The Problem
Delivering the right amount of ventilation
to the right rooms in the right location.
The Solution
The Outstanding Joist System
The Posi-Joist open web floor system will allow
you to deliver the right amount of ventilation
to the right rooms in the right location in the
simplest of ways.
The advantages are clear:
• Open web design provides easy access for the
design and installation of services
• Improved quality of service fitting, eliminating
costly remedial work
• Greater clear spans for design flexibility
• Clear profit from savings in labour, time,
materials and call-backs
• The largest network of licensed manufacturers
throughout the UK and Ireland
CPD Now available for Posi-Joist
Contact MiTek today or visit
www.posi-joist.co.uk for full
details and an on-line presentation.
MiTek House
Grazebrook Industrial Park
Peartree Lane
Dudley
DY2 0XW, UK
Telephone: 01384 451400
www.mitek.co.uk

Article >
Building momentum
Bruce Meechan reflects on some of the news and views from the recent Explore
Offsite conference staged at the NEC Birmingham.
There was a slightly embarrassed pause
when the Minister for Housing, Brandon
Lewis, completed his short speech
welcoming the throng of delegates who had
assembled in one of the gallery suites at the
Atrium end of the NEC: not because of
anything he had said, but because he had
chosen to send a video message rather than
attend in person as he did for a similar event in
the capital a year back.
The moment of uncertainty, I am certain, was
delegates wondering whether they should
applaud a pre-recorded image, though just as
assuredly his words will have given everyone
confidence that the Government still very much
backs modern methods of construction – and
better building in general, despite the retreat
from Zero Carbon homes.
> The government continues to promote house
building and off-site agenda
Unavoidably absent due to Government
business, the MP for Great Yarmouth, who was
handed the portfolio for housing and planning
during the later stages of the Coalition, spoke of
the challenges facing the housing industry due
to the very high demand for residential
accommodation. And while remarking that he
backed all methodologies for the delivery of
housing, he significantly referred to the need for
speeding up the length of time it takes to build
them. “The initial build cycle of 20-24 weeks,” he
said, “has to be trimmed to just a few months,
maintaining high quality and led by customer
choice.”
He went on to refer to the skills gap and how the
UK can bring more people into the industry, and
establish factories able to produce the systems
needed to meet demand. “I believe that your
conference offers a huge opportunity for the
people here today to play their part in the
solution to how we deliver more homes, of high
10
quality – to design and build more quickly than
we have in the past.”
The keynote speech was in effect actually
delivered by the legendary guru of
redevelopment, the founder of Urban Splash,
Tom Bloxham. Obviously his early projects
focused on the conversion of some landmark,
often industrial buildings, where Modern
Methods of Construction were not appropriate;
and he confessed himself to not being either an
advocate or decrier of such solutions. They
tended, he said, to still prove costlier than
traditional trade routes, but confirmed: “What
we have found is that the advantages –
particularly in terms of quality, in terms of
capability, in terms of design - is why the
majority of our projects, going forward, will be
using offsite, and indeed fully modular
construction.”
Tom Bloxham went on to talk his audience
through a mix of his well-known and some
slightly less high profile projects; explaining their
negatives as well as positives, and how his
company had succeeded in riding out the
recession by delivering schemes which people
wanted to live or work within.
The baton was passed next to Rory Bergin of
HTA Design who offered the opinion that
manufacturing promotes cooperation rather
than confrontation; and praised the
professionalism of the manufacturers and
developers with whom he had worked over the
> The founder of Urban Splash, Tom Bloxham
past five years “pushing the boundaries of
volumetric construction.” He also added that
“our relationship with the teams gets stronger
with every project,” and spoke about the
potential of modular for creating some of the
very tall buildings which are planned for London
and other major cities where his practice has
offices.
The tempo of the debate was raised just prior
to lunch by what the event’s chairman
described as a “double header”, but which
turned out to be something more like a doubleact
with spokesmen from Barratt Homes and
Stewart Milne discussing the way in which the
two business had worked together on
facilitating projects, particularly north of the
Border.
Stewart Milne of course products both the
‘traditional’ timber frame in the form of open
panel, and the more offsite intense closed panel
systems. The two spoke of both the learning
processes and all important information
sharing, as well as the fact that an attempt to
‘superimpose’ a set of standard house types
onto timber frame methodology had to be
abandoned in favour of producing a series of
special details; right down to the inclusion of
gas services.
The overall message from the morning’s
speakers seemed to sum up the need for the
various parties in the supply chain to work
more closely and collaboratively, from the very
earliest possible stages of a project. The
delegates, including myself, then had the
chance to visit the stands set up by a couple of
dozen exhibitors in the space outside the
conference hall as they took some
refreshments.
Having also been involved with our sister
publication, HA or Housing Association
Magazine since its launch, I was also very
interested to hear the comments of a senior
representative from one of the big
housebuilders during a panel discussion later
on in the day.
Ever since the Waverley publications began
covering the offsite industry in the late
nineties, we have been hearing from
manufacturers about the sense in taking
advantages of the economies of scale, or in
other words, avoiding late alterations or overcomplexity
in terms of layout.
By contrast the speaker referred to social
housing specifiers being guilty of continual and
unnecessary customization of designs which –
worryingly – resulted in their schemes costing
double or more the price per square metres
which our volume housebuilders are willing to
pay.
The event at the NEC showed just how much
the offsite market is maturing in terms of
capacity and capability, but also reminded us
how much we have to learn in respect of the
way we make use of the manufacturer’s various
solutions.

Current large scale developments such as at NW Bicester
are making full use of modern methods of working
MMC May 2016 11

Article >
Timber now growing on developers
Andrew Carpenter, Chief Executive of the STA, offers MMC’s readers an insight into the health and
ambitions of the structural timber industry.
of Igloo. Andrew observed: “When you look at
self-build or Custom Build, where you’ve got a
client who has a choice of what building
materials to use, three out of four choose
timber. That is for a variety of reasons:
certainly energy efficiency, and certainly for
lack of defects.”
There have also been new entrants into the
structural timber market as Andrew alluded
to: “The fact that Legal & General Homes has
just invested £55 million in a new CLT (crosslaminated
timber) plant just outside of Leeds
proves that it is really happening. An
insurance company wouldn’t invest that sort
of money if they didn’t believe there was
going to be a good return.”
> A timber frame system being erected on site
Importantly, not only is the demand there for
engineered timber solutions, but the capacity
Housebuilders are notorious for
concentrating on the bottom line and
only building the number of homes
they are certain of selling – which is why
modern methods of construction vanish
from their minds during a downturn. This
time round the economic cycle, however, it
seems possible that thanks to factors like
energy standards and shortages of
traditional skills, timber frame has
established a critical share of the market.
Andrew Carpenter, Chief Executive of the STA
told the magazine: “From the point of view of
structural timber all the signs are pointing to
the sector enjoying a period of sustainable
growth. In 2010 we had 22-23 per cent share
of 100,000 homes, we are now moving
towards having a 30 per cent share of
200,000 homes being built in 2020; so some
60,000 homes from ten years prior. This is
the size of the opportunity which is in front of
us – figures supported by both the NHBC and
LABC who actually saying they are
experiencing unprecedented levels of activity.
“Part of this stems from the fact bricklayers
and block-layers were scarce, but I believe
that speed of build has now become a priority
again for developers. Obviously timber frame
and other offsite solutions are now a major
advantage.”
Andrew Carpenter believes there is also a
genuine political desire to get significant
numbers of additional new homes built. He
said: “For the first time the politicians are
wanting to remove any obstacles to growth,
and we heard from (STA member) Barratts
that in their view this is the most planning
12
friendly government ever. While I have just
been involved in a survey for Boris Johnson
here in the capital, regarding removing
obstacle to building upwards. So all the signs
at the present are in our favour.”
Quizzed about whether Government might be
leaning towards timber framing because of its
sustainability credentials, Andrew explained
that he felt the official backing was for
modern methods of construction in general.
“There is an understanding amongst
politicians,” he said, “that if they want to build
new homes quickly, then offsite is the route
forward. I have sat on two round tables in the
recent past set up
by the
Housing
Minister,
Brandon
Lewis
and the
Deputy
Mayor
of
London,
looking at
how to build
homes more
quickly with offsite. Not timber frame
specifically, though timber frame does
represent 90-95 per cent of offsite, so it will
follow.”
Andrew Carpenter went on to speak about the
growing importance of self-build to the overall
housing delivery picture, and the
Government’s backing for ‘Custom Build’
which is being led by people like John Sawyer
“There is an understanding amongst
politicians, that if they want to build
new homes quickly, then offsite is the
route forward. I have sat on two round
tables in the recent past set up by the
Housing Minister, Brandon Lewis and
the Deputy Mayor of London, looking
at how to build homes more quickly
with offsite. Not timber frame
specifically, though timber frame does
represent 90-95 per cent of offsite,
so it will follow.”
Andrew Carpenter,
Chief Executive of the STA
of the industry has been increasing steadily
since the recession eased. Membership of the
STA has also grown strongly since the
association was formed from the
amalgamation of former trade bodies such as
the UKTFA. Indeed the STA believes it now
represents some 80 per cent of the UK’s
structural timber manufacturers by market
share.
Andrew added: “Significantly we have
increased the scope of the membership to
embrace other elements of the supply chain
including housebuilders, architects and
contractors - who all want to be part of the
Structural Timber Association which helps
enormously in terms of the knowledge bank.”
If you want to know more about the
potential for structural timber visit
www.structuraltimber.co.uk

DEPEND ON:

AN AI IR TIGHT OSB SYSTEM YOU CAN
DEPEN ND ON, ALL WRAPPED UP IN
ONE
PERFECT PACKAGE
SMARTPLY PROPASSIV
is a fully certified rtified, zero added formaldehyde, structural, air and vapour
tig ht OSB panel system for the const ruction of Passivhaus and Low Energy buildings.
To
find out more or request a produc ct sample, call 01322 424900 or visit MDFOSB.com

Low Carbon, Fabric First >
Why is breathability so important?
When we talk about “breathability” in buildings, we aren’t referring to the movement
of air within a building, rather the movement of water.
There are four basic areas where the effect of water on building performance is considerable:
• On the outer surface: rain penetration
• In the fabric: interstitial conditions
• On the inner surface: surface condensation
• Inside the building: indoor air quality
Water moves in and out of buildings constantly as both a liquid and as a gas, and is practically
everywhere. Water affects everything in a building from the robustness of the building fabric,
through to the thermal performance of the building and the health of occupants. As we have
increased the airtightness and thermal performance breathability has become a critical issue. All areas of new build and retrofit are affected by it, so
it is crucial that we get it right. It is clearly as important as delivering good thermal performance, with high profile projects, such as Oxley Woods in
Milton Keynes, now costing the developer upwards of £12M after moisture related failure, or timber frame houses in Wales that are now being pulled
down due to the wrong material being used. See BRE Wales report; Colin King 06/03/2014
A strategy for dealing with water in the air and in the fabric is now central to the success or failure of the building.
Why is moisture so harmful?
Damp external walls can have considerably lowered thermal resistance, while surface and interstitial condensation within a building causes moulds
which are harmful to our health and fabric decay. To solve this challenge, we need an effective strategy;
• Ventilate the building correctly.
• Do not rely on a strategy of preventing moisture getting into the building fabric, it will !
• Make sure moisture can get out and more quickly than it got in; fail safe.
• Do this by insuring the right combinations of products in a given context. Different parts of the UK require different considerations.
SPI’s expanded polystyrene passive house
foundation solutions
SPI are one of the leading manufacturers
of expanded polystyrene in the UK,
supplying an extensive range of
building and civil engineering products. With
state of the art moulding and cutting
machinery SPI can offer a wide range of
grades and bespoke products to suit all types
of projects.
As an insulation supplier SPI have seen trends
in correlation with the increasingly demanding
building regulations of part L conservation of
fuel and power. Even after the scrapping of the
2016 zero carbon policy there is still a
requirement to meet the 80% reduction in
carbon emissions by 2050 under the Climate
Change Act. There has been a call for
innovative solutions when it comes to
insulating the UK housing stock, the
development of building systems which
produce lower target U-Values has allowed for
off-site construction to bloom, with a growth of
products like SIPs, ICF walls and modular floors.
Recently this has lead to an increase in passive
house foundation construction largely
developed as offsite modular concepts, which
allows for less installation time on site meaning
the structure above can be installed earlier.
Typically the foundations and structure can be
completed within a week for a 4 to 5 bedroom
house. Passive house foundations consist of a
basic L shaped perimeter with standard boards
up to three layers thick. Specialist clips are
used to hold the whole foundation system
together. The complete foundation base is then
covered with a DPM and the structural concrete
can then be poured.
Once the concrete is cured the superstructure
can begin. Most commonly we have seen these
foundations used with SIPs and lightweight
timber frames. As an insulation provider the
off-site development means we can cut
bespoke products required by the layout of the
build quickly and easily, making the whole
process from conception to completion
exceptionally fast.
These types of building elements and forward
thinking innovations offer a certainty that
builds can easily exceed regulations which
when coupled with the environmental
sustainability expressions of modern future
proof housing make the prospects of a carbon
neutral 2050 attainable.
www.styrene.biz
16

If moisture gets into your building
fabric it must not get trapped.
The external shell of a building is
much like a coat, it needs to keep
the rain off, but like a GORE-TEX ®
jacket, it must allow moisture,
produced internally, to
get out
of the building fabric.
Breathability
Traditional construction relies on a vapour barrier
to stop the moisture getting in, but this approach is
®
now seen to be failing. P avat ex is the GORE-TEX ®
of buildings, delivering thermal performance and a
failsafe solution that prevents moisture building up
in the building fabric.
®
P avatex is the
GORE-TEX ®
of buildings.
Keeps the
building warm
and the timber
structure dry.
For full details and
nearest distributor call
01844 338338 or visit
www.natural-building.co.uk
Pavatex woodfiber on CLT, Arcadia Nursery, Edinbur
gh

Low Carbon, Fabric First & Passivhaus >
WDH - Awake to the benefits of building offsite
Building infrastructure in the UK is under review once again – the recently created National Infrastructure Commission is due to
deliver its first report shortly – and better insulation of homes is one of the areas it could address as a part of its wider remit.
Here Mike Stevenson Development
Director of offsite fenestration
specialist Sidey tells us about their
work with WDH in Wakefield through its inhouse
construction team, Homebuilder, which
has already delivered greater
thermal efficiency for its
residents on a new-build site in
the town as just one of the
realisable benefits of building
offsite.
For WDH there was a desire to
deliver truly energy efficient
social housing in its most traditional
sense – not just properties for rent but
genuine social housing delivered for long term
residents. Homes with a true social value.
Commenting for WDH, Homebuilder manager
Adam Green explained “As one of very few
housing associations delivering new properties
we are developing homes to be proud of, at a
reduced cost with a build quality that is more
thermally efficient and will help tenants avoid
fuel poverty.”
The 39 dwellings built at Ripley Court are in
fact a case study of how to access all the
benefits that can be achieved through building
offsite.
Mike takes up the story “It was clear that WDH
had a real understanding of the value to their
residents of building to a high specification and
that they understood how building offsite could
deliver this for them cost effectively and in line
with their time-scales”.
“Our involvement with the scheme at Ripley
Court came out of long term discussions we
had been having with the Homebuilder team
about the many benefits to be had from
installing high specification windows in the
factories of offsite manufacturers with the time
and costs savings and the efficiencies in
process which installing windows this way
would bring”.
“Through those ongoing discussions it became
obvious that through collaboration with the
right supply chain using innovative low risk
solutions WDH Homebuilder and Sidey had real
synergy and could deliver win:win results. We
are both big on collaboration as the driver to
maximise technical and supply chain efficiency,
so after having completed a more traditional
site together we were delighted to get involved
with a true offsite scheme”.
“WDH’s culture being what it is, they brought
other supply chain partners to the table with
the same outlook and approach. It transpired
18
that several of these companies had worked
together on other schemes for other clients.
These companies included the foundation
system, structural timber frame manufacturer
and the air tightness specialist along with
Sidey”.
“The absolute key to successfully
realising the benefits of building
offsite is for partners in the supply
chain to have design team
involvement and WDH drove this,
actively encouraging it from the
outset with all parties working with
both their in-house design team and
external architectural partner”.
“The scheme really benefitted from the
discussions between ourselves, the architects,
the timber frame manufacturer, and the airtightness
solutions supplier. It meant we could
design and deliver the optimal specification to
WDH without compromise. It was a true offsite
development rather than having to convert a
previously designed ‘traditional build’ scheme
to offsite construction”.
“WDH adopted the innovations we suggested,
following thorough due diligence, to help realise
the overall benefits. This included using our
patented KitFix ® bracketing system – which
enables windows to be fixed into the apertures
of the timber frame panels at the offsite
manufacturers premises. The windows are
‘contained’ within the panels in a transport
position enabling the panels to be stacked,
banded, and transported to site as normal”.
“The structures were wind and watertight
immediately the panels were erected allowing
follow-on trades to commence earlier while the
windows being delivered in the panels meant
there was reduced overall site traffic, reduced
site attendance and reduced Health and Safety
risk by removing the traditional impact of site
delivery and manual handling of windows”.
“Ripley Court is an ‘exemplar’ of what can be
achieved when the client/developer drives a
collaborative agenda. Others should look to
this scheme as the benchmark for how to
deliver outstanding technical performance and
thermal efficiency coupled with financial and
delivery predictability”
“WDH is clearly awake to the benefits of
building offsite – others should follow their
lead”.
Mike Stevenson is Development Director of
offsite fenestration specialists Sidey.
www.sidey.co.uk

JJI-JOISTS. made
TO make YOUR
JOB EASIER.
We’ve thought of everything so you can just get the job done. JJI-joists offer a stock range of depths from 145mm to 450mm.
The best design software and technical support are included. We are FSC and PEFC certified and PAS 2050 accredited. Our UK
manufactured I-joists are also fully BIM compatible. So, whether you’re designing or building, the job’s easier with a JJI-Joist.
WEB: www.jamesjones.co.uk/ewp
EMAIL: jji-joists@jamesjones.co.uk
MMC May 2016 19

Low Carbon, Fabric First & Passivhaus >
Triple timber solution to sustainability
Technical Editor Bruce Meechan looks at the range of very low carbon solutions available from a major
timber frame manufacturer based on the Shropshire - Mid Wales border.
> Lowfield Timber Frame has
collaborated with leading
architects on numerous
projects targeting very low
energy consumption and
can offer three different
walling solutions which
could contribute to
PassivHaus designs.
As an offsite manufacturer working
across a variety of sectors including
commercial, residential and education,
Lowfield Timber Frame is well used to being
presented with different technical challenges;
and to meeting them through the use of
different solutions that reflect the versatility of
what is arguably nature’s most versatile
material.
In essence, Lowfield has in recent years,
responded to the demands of both clients and
architects for PassivHaus and Near-to-Zero
carbon buildings employing twin-wall timber
frame, structural insulated panels (SIPs) and
now a closed panel system based on timber I-
joists.
Darren Jarman, Managing Director for Lowfield
Timber Frame, told MMC Magazine: “We have
an extensive product range that enables us to
respond to clients targeting PassivHaus
standard or other very low energy solutions;
and we will work with their architects and
assessors or other specialist consultants in
order to ensure all the details – such as the
floor wall junction or foundation connection,
achieve the required levels of insulation.
“Some ten years ago we supplied a twin-wall
timber frame system for the principal of Munro
Associates who was building a new home up in
Pitlochry, Scotland. That achieved the level of
U-value necessary for PassivHaus - by filling
with Warmcel recycled newspaper insulation;
and now we are working with PYC Warmcel on a
solution featuring 300 mm thick I-joists
supplied by Metsa Wood for a social housing
scheme featuring low rise homes. We have also
20
built to PassivHaus standards using the
Kingspan TEK system; so our product range can
really cover all the bases and offer clients
solutions to suit their individual needs.”
“We have an extensive product
range that enables us to respond
to clients targeting PassivHaus
standard or other very low energy
solutions; and we will work with
their architects and assessors or
other specialist consultants in
order to ensure all the details –
such as the floor wall junction or
foundation connection, achieve
the required levels of insulation.”
Darren Jarman, Lowfield Timber Frame
The architect, Mungo Munro commented: “We
do a lot of work for housing associations as well
as clients in other sectors, though this was a
self-build where Lowfield produced a timber
frame to my own design. I went for a double
timber frame as it virtually eliminates any coldbridging
and achieved a U-value far better than
the Building Standards required.”
Amongst the other highly sustainable projects
Lowfield Timber Frame has helped deliver
recently is the Telford Town Park Visitor Centre,
offering bicycle hire and a café as well as
classroom space. The original intention was to
build the walls from straw bales, but the cost
would have pushed up the budget so the
specification switched to the Kingspan TEK
system.
The jointing arrangement for the SIPs system
helped keep the air leakage rate to around 1
m3/m2/hr at 50 Pascals. The addition of a high
performance vapour control layer as part of the
building envelope meant the overall
airtightness figure for the finished structure
outperformed the PassivHaus requirement at
0.58 m3/m2/hr. In terms of insulation value,
combined with Kingspan Thermawall TW55
boards, the U-value for the Tek walls was 0.14
W/m2K.
Lowfield also contributed to the conversion of
an eyesore, asbestos-clad packing shed into a
stunning studio on the outskirts of Leamington
Spa; which earned the architect, Sjolander de
Cruz, the RIBA Sustainable Project of the Year
Award.
www.lowfieldtimberframes.co.uk

Shanghai Art & Design Exhibition:
airtightness
Wraptite-SA airtight membrane has been selected by RIBA award
winning development pioneers ZEDfactory in an innovative solution
to deliver zero carbon housing to China. The ZED Pod home has been
built as part of
the Shanghai
Art & Design
Exhibition at
the Shanghai
West Bund Art
Centre.
Wraptite-SA,
self-adhering
vapour
permeable air
barrier was
installed as part
of the panel
construction of
the home. The use of Wraptite-SA in the construction makes a
significant contribution to a building’s thermal performance by
preventing air leakage. It also provides high vapour permeability in a
continuously sealed, self-adhered, airtight membrane.
Wraptite SA is applied externally, quickly and easily to the OSB
boards in continuous pieces. The membrane fully bonds to virtually
any substrate, requiring no mechanical attachment, seals or tapes to
suppress air leakage around junctions or penetrations. Wraptite-SA’s
high vapour permeability allows damp sheathing to dry quickly and
moisture vapour to escape. This ensures good indoor air quality and
reduces the likelihood of mould, mildew, condensation, timber
distortion and metal corrosion.
www.www.proctorgroup.com/air-barriers
Acme clay plain tiles used for
pioneering zero bills home
An innovative, affordable zero bills home created by architects Zed
Factory, is using Acme clay plain tiles from Marley Eternit to help
meet strict sustainability criteria.
Zero Bills aims to be the first commercially viable home with no
net annual energy bills and enough surplus electricity to power a
small electric car. Built with traditional construction materials, Zed
Factory has incorporated high levels of energy efficiency and
renewable energy into the design. A mansard roof has been
created with a clear integrated photovoltaic roof on one side and
Marley Eternit’s Acme single camber clay tiles in Red Sandfaced
and Red Smooth on the other.
Daniel Weait, specification manager at Marley Eternit, “We are
proud that using our products helps architects and housebuilders
to get credits
under the
environmental
section of the
Home Quality
Mark. As one of
the first homes to
be assessed
under the new
HQM scheme, we
hope to see the
Zero Bills Home
being offered at
developments
across the
country.”
www.marleyeternit.co.uk
MMC May 2016 21

Low Carbon, Fabric First & Passivhaus >
Polarwall launch offsite construction system
utilising the concept of flying factories
Large panels (2.5m x up to 3m high) of
the Polarwall Insulating Concrete
Formwork are assembled either offsite
or in a temporary assembly facility which can
be allocated near to or at the site.
If there is a crane on site then the panels can
be “gang formed” together in lengths of up to
12.5 metres and lifted into location.
Reinforcement can be incorporated into the
panel assembly making it ideal for basement
construction and retaining walls.
A new internal walling system from Polarwall is
also being used. This uses cement fibreboard
panels as permanent shuttering and will create
a wall which is virtually finished.
A new site has opened in Slough where this
revolutionary build method will be showcased
to any interested parties. As part of the Flying
Factory concept this project will have its own
concrete batching facility on site for filling the
assembled Polarwall formwork and for the
floors.
The Slough project has 80 apartments, retail
space and underground car parking. The
contractor M2 Construction is aiming for a fast
build construction with a target time of 2 weeks
for each floor.
Contractor Andrew Skinner says that “Using
the large panels is a very exciting development
for us. We have used the Polarwall formwork
almost exclusively for the last three years. It is
already a very impressive construction material
and provides structures that comfortably
exceed all Building Regs requirements both in
terms of thermal performances and structural
strength. Now, by using the large panel
assembly we have moved this up a gear and the
build speeds are becoming incredibly quick.”
Polarwall Technical Director Alan Wheeler said
“The pre-assembled panels are now getting lots
of attention from larger contractors who are
primarily interested in two things – the use of
less-skilled labour in the build and also the high
build speeds that can be achieved. The panel
system lends itself to larger projects such as
light commercial, schools, apartment blocks
and multi-unit developments. One contractor is
particularly interested in using our products in
association with timber frame where we would
provide the high strength structure in the lower
stories and timber frame would be used on the
upper stories.”
The site will be having open days for
interested parties who should in the first
instance contact Polarwall (01392 823300
www.polarwall.co.uk) to arrange.
Airtight solution for landmark development
Sika-Membran has enabled thousands of windows to be installed at New Providence
Wharf, a stylish residential complex in Canary Wharf, with an air and weathertight
seal around an estimated 22,000m2 of façade.
Sika-Membran, from global building product manufacturer Sika, is a versatile EPDM
synthetic rubber waterproofing membrane, designed to provide an efficient method
of sealing construction gaps in building façades. Thin and easy to use on site, the
system offers long term performance, and used in conjunction with Sika’s SikaBond
TF Plus N adhesive it offers an ultra-strong bond to create an airtight seal. Solvent
free, durable, UV and ozone resistant, and 100% waterproof, it can be bonded to
most building substrates. Being highly elastic, it can be used on uneven substrates,
making it suitable for the most demanding project. The system has also aided in
the acoustic performance of the building by helping to minimise outside noise.
www.sika.co.uk
22

TENMAT
INNOVATIVE FIRE
PROTECTION PRODUCTS
AND SOLUTIONS
Winner of the Queen’s Award for Innovation and International Trade
Firestopping for External Cavities
Firestopping for Lighting Fixtures
Firestopping for Ventilation
Firestopping for Pipes
Firestopping for Electrical Services
TENMAT Ltd
+44 (0)161 872 2181 • info@tenmat.com • www.tenmat.com
Intelligent
Airtight and
Windtight
building
systems
UNI TAPE,
TESCON No. 1 and
TESCON VANA
have now officially
passed the 100 year
ageing test
100
YEARS
Confirmed by Tests
Permanent airtightness with pro clima!
Tested for the entire usage period
Reliable functioning tested for 100 yrs
exceeded
UNI TAPE
TESCON No 1
TESCON VANA
T. 01228 711511
info@ecologicalbuildingsystems.com
www.ecologicalbuildingsystems.com
The tapes have been independently tested for artificial ageing at
the University of Kassel.
The tests confirm the high quality and durability of the
waterproof SOLID ACRYLIC adhesive glue used in the pro clima
tapes.
MMC May 2016 23

Article >
Factory installed fire protection
MMC Magazine examines the potential of a proven fire-stopping product range to help offsite
manufacturers protect their systems against the spread of flame and other products of combustion.
Prefabrication is viewed by many in the
industry as the best means of ensuring
new properties match up to their
target performance standards in terms of
insulation and airtightness, but the controlled
conditions of a factory environment also offer
the opportunity to optimize the fire
engineering of structures. And this is an area
where Manchester based Tenmat UK can offer
its considerable experience and expertise.
The company whose Firefly range of Ventilated
Fire Barriers, Fire Sleeves and other
intumescent products are widely used on sites
around the country, is also specified by some of
the UK's largest offsite specialists.
Furthermore, the company has the
development facilities and the resources to
take a new concept from a client and develop it
into a fully tested product solution.
Penetration Seals for Pipes & Ducting, as well
as fire protection for Downlights and Electrical
Services.
Tenmat also supplies bespoke intumescent
barriers to the manufacturers of electrical
consumer units and offers a solution to not
only protect the area where switches have been
recessed into a wall, but also prevent them
being a path for air leakage.
Mark Davies continued: “Our wide range of
products are accredited to all the latest British
and European standards and are independently
tested by BM TRADA to ensure they will
perform in practice.
Fire protection products should meet the most
stringent standards and be made under strictly
controlled production processes. This is
achieved by Tenmat through rigorous internal
and external auditing; which is why we are
regularly invited to take part in fire safety
committees and stakeholder groups.”
www.tenmat.com
“In terms of the offsite
sector, we are seeing our
products used extensively in
projects such as the
construction of high-rise
student accommodation
blocks in locations
throughout the UK.”
Mark Davies,
Product Manager for Tenmat
Mark Davies is Product Manager for Tenmat
and recounts: “We provide viable, installer
friendly fire protection products to clients right
across the building industry, including the trade
contractors such as bricklayers and electricians
who want products which are quick and easy to
fit. Our range enables areas such as cavities
and service penetrations to be protected while
we are also used to catering for the differences
in building regulations.
“In terms of the offsite sector, we are seeing
our products used extensively in projects such
as the construction of high-rise student
accommodation blocks in locations throughout
the UK. On some contracts the products will be
employed both during the factory fabrication
process and also when installing the
mechanical and electrical services on site.”
The options employed include Ventilated Fire
Barriers which can provide
compartmentalisation in the external wall for
up to 2 hours. Other products include
> Tenmat has a proven track record working with some of the UK’s biggest names in
offsite and a product range able to protect structures against the spread of fire as
well as help achieve the required levels of airtightness and acoustics
24

Caledonian secures £13m turnkey contract for ACS Cobham
International School
Caledonian wins £13m contract to deliver a new student
accommodation block for leading local and global
educator ACS Cobham International School. As principal
design and build contractor, Caledonian will take responsibility
for the end-to-end delivery of this cutting-edge new building, to
be completed by June 2017.
Designed by Broadway Malyan, this all-new facility will complement
the school’s existing boarding house, set in 128 acres, providing an
additional 113 bed spaces (all in premium single and double rooms).
Supervisor accommodation, study areas and common rooms in
addition to the student bedrooms complete this ergonomically
designed, eye-catching four storey building.
Caledonian will start work on the full turnkey package in the next
few weeks, comprising the new build stand-alone boarding house
and associated external works, encompassing a blend of traditional
and modular construction. The accelerated offsite programme will
reduce the construction period by 40% and will deliver the facility
in time for ACS Cobham to have the additional boarding provision
available for the start of the new school year in 2017.
Caledonian CEO Paul Lang comments “this is a significant project
for Caledonian, not only will we be responsible for the
manufacture and construction of the modular components of the
building, but we will also demonstrate our credentials as a
principal design and build contractor”.
Ian Jones, Senior Project Manager for ACS Cobham adds
“renowned for innovation and pioneering the provision of high
quality education, ACS selected Caledonian for the outstanding
quality of their work, the efficiency of their manufacturing process
and the significantly reduced levels of disruption their approach
affords our rich school life”.
ACS Cobham offers a rigorous curriculum including the prestigious
International Baccalaureate Diploma and US-based Advanced
Placement to 1,500 students from over 70 different nationalities.
The new boarding house development and current house
refurbishment, underlines their reputation as a premium school
residency programme provider.
ACS Cobham have launched a dedicated web page to keep
current and prospective parents, staff and students up to
date on progress:
www.acs-schools.com/boarding-house-development
MMC May 2016 25

Article >
Cold-roll renaissance
Technical Editor Bruce Meechan visits Britain's traditional ‘metal-bashing’ heartland
to discover how one company is giving steel framing a very modern ring.
Having paid a brief visit to Metsec’s
stand at the Offsite exhibition prior to
Christmas, I accepted an invitation from
the company’s Marketing and Business
Development Director to visit the premises at
Oldbury in the Midlands: to find out more about
its divisions which embrace dry-lining systems
and cable management systems as well as high
performance purlins and light gauge steel
framing for all types of building structure.
> Metframe walls normally carry concrete floors cast on composite metal decking to provide
excellent fire and acoustic performance, whilst maintaining the speed of build.
Despite the company's strong performance over
recent years - defying the downturn in
construction after the financial crisis – Richard
Allen still sees two rather illogical barriers to
even better growth figures, which he is trying to
address.
The first came to light during a series of focus
group meetings involving industry professionals.
These revealed that the name 'Metsec' is
commonly used in construction as a verb or
generic term - including by some people who
didn't know the manufacturer actually existed.
The second, though, could be easier to
understand, given the construction trade’s
notorious reluctance to adopt new practices:
even when there are many good reasons for
doing so. Richard reflected: "Despite the
potential for steel framing to save them time,
cost and hassle, some people still perceive there
is a risk to using a non-standard method of
construction. Their reluctance to adopt modern
methods of working - normally by reverting to
in-situ concrete - means they are missing out on
the cost and programme savings which could be
afforded to them. The lightness of the Metframe
system can allow you to employ shallower
foundations as well as offering great acoustic,
thermal and fire performance. And overall you
can just build that much faster than with a
reinforced concrete frame.”
So how does the Metsec offering deliver these
many benefits? “When you look at the products
that we sell,” Richard explained, “in essence
there is nothing that complicated about them.
Our Metframe system for instance features coldroll
formed C and U-sections; the complexity
comes in understanding how they work together
to create a 12-storey structure.
"It is very much in our design capabilities that
we add value for our customers, and why Metsec
has come to be regarded as a thought leader
within the sector. We have some very clever
engineers using the latest design software:
including TEKLA and Revit.”
Responding to the industry’s bilateral use of UK
and European standards, Metsec’s software
allows projects to be designed in line with either
the British Standard or Eurocode. Its range is
also CE marked to Level 4.
He continued: “When it comes to our purlins
systems we aim to make the structural
engineer's life easier, offering them free
software for designing the different systems. For
instance inputting the building’s location will
automatically take account of typical snow load
and wind loading for the area. Then given the
building’s dimensions it will calculate the most
efficient purlin design, using the optimum
amount of steel.
“Then for the fabricators, they want something
which is easy to erect; where the logistics are in
line with the build programme. Because we
operate on a very short lead time, we can adjust
delivery dates to match any problems they
might have with the weather or variations from
the client.
“It is design expertise which enables us to carry
out all of our contracts in such a way that we
can create cost savings for our customers. Take
for example Smithfield in Manchester - our
ability to map out the full elevations to the
building for the client, and seeking ways to value
engineer the design meant we were able to
remove a considerable amount of hot rolled
steel - offering Galliford Try real cost savings.
Elsewhere our lightweight steel framing systems
have had a lot of success using our infill walling
system with student accommodation as well as a
number of social housing projects: and we are
keen to do more."
> Metsec head offices and manufacturing facilities in Oldbury
Across all of its different divisions, Metsec's
interaction with consultants and clients is led by
its specification sales teams, all of which - with
the exception of dry-lining - are split up
regionally.
www.metsec.com
26

"It is very much in our design capabilities
that we add value for our customers, and
why Metsec has come to be regarded as
a thought leader within the sector. We
have some very clever engineers
using the latest design
software: including TEKLA
and Revit.”
Richard Allen, Marketing and
Business Development
Director, voestalpine
Metsec
MMC May 2016 27

Be a hero with Zero!
Powerwall Group, to deliver a step change reduction in the cost of zero
energy bills homes whilst providing fixed price development solutions.
The idea is to provide a one stop
shop for potential clients. The
intention is to provide both
individuals and developers with fixed price
standard house types and development
solutions, with economies of scale clearly
available offering the best possible
specification for the price. The
Powerwall system will meet Code 6
EN01 and can meet full Code 6 when
tailored to fit each unique site context.
The Powerwall factory will fix its fees at
competitive rates based on the contract
value, and will be employed by Powerwall.
We would seek to offer multi-disciplinary
services and include Engineering, M&E and
QS Cost Management services in all
appointments where appropriate.
Powerwall has a fixed supply chain and
fixed costs for many items (with all
installation and site based labour provided
by the main contractor). These items
include the Energy Roof rain screen
including BIPV roof, Power Wall heat hub
with integrated ASHP, ancillary compressor
driven hot water production and storage
and MVHR ventilation supply unit plus
proprietary air ductwork distribution, and a
Viking Foundation system, triple glazed low
E Windows and Doors, and an external
insulation system and stud timber frame
system.
Powerwall is able to procure items on a
project by project basis, tendering for local
products and services, and achieving best
value without compromising the low impact
environmental credentials, durability,
performance, or embodied carbon
footprint. Items would include the 140mm
stud timber frame system filled with Knauf
Ecose frame bat insulation; all mechanical,
plumbing and drainage services; external
works, landscaping, bin stores, log stores,
garages with pre-grown sedum roofs and
timber clad doors; electric vehicle charging
sockets; all roads, pavements, bollard
mounted external lighting; full responsibility
for commissioning the completed buildings
and achieving sign off from NHBC, LABC,
Premier, BuildZone or Global Home
Warranties insurance backed, which meet
mortgage companies’ lending
requirements.
This split of responsibilities should be
workable, and clarifies which items and
specifications are fixed, and which are
flexible to allow the
Powerwall procurement
purchasing initiatives.
The share/profit split to
Powerwall and the local
contractor must reflect the
total services input of all
parties as a direct ratio.
This should ensure
sufficient motivation for
the local contractor to
maximise their profit
without devaluing the
Powerwall brand.
A supply agreement with full specification
and volume discounts is now set up,
including an audited compliance model
demonstrating that the non site specific
building fabric and energy systems meets
Code 6 EN01 with the optional capability for
site specific contextual masterplans, and an
audited building physics model setting
energy load targets applied to a range of
standard house types.
The agreement also includes a set of
standard construction details already with
SAP thermal bridging and NHBC, LABC,
Premier, BuildZone or Global Home
Warranties insurance backed sign off,
foundation and insulation systems, heating
and energy systems and many more –
check the website for the full supply
agreement.
What is most important is that we build,
register and protect the standards of the
Powerwall Brand on every project. The
plan is to set up a new standard for zero
energy bills housing that becomes the
market leader.
We are looking for contracting companies
who will take the above kit of parts and
give clients fixed price turnkey solutions
without Powerwall taking contracting
risks. We supply the Powerwall
ingredients, do the design and supervision
plus site inspection, and the contractor is
responsible for sourcing and installing the
rest of the scope of works. The joint
venture contractor can be chosen to suit
the size of project.
The Powerwall Group supply multiple
zero energy systems such as Timberframe,
Sips, light Gauged Steel (LGS), Insulated
Concrete Formwork (ICF), Cross Laminated
Timber (CLT) and traditional building
systems.
Contact Powerwall on 0203 824 0600 -
mobile 077108 22196 or email
jpm@powerwallgroup.com
28

A division of the
Powerwall Group
www.powerwallgroup.com
Tel: 0203 824 0600

Steel Framed Building Systems >
Wernick buildings provide striking new
centre for goals
Goals Soccer Centres PLC has over 40
centres in the UK and is the largest and
most successful operator of dedicated 5-aside
football pitches in the world. Each centre has
a minimum of 10 enclosed floodlit arenas with the
latest synthetic grass pitches. Their aim is simple;
to get more people on the pitch, playing more
football every single day and they are always
looking to expand to further meet that aim.
Priding themselves on providing the best facilities
possible for the players, Goals approached Wernick
Buildings to deliver high quality buildings in tight
timeframes. The centre in Doncaster is one of a
number of projects Wernick have been involved in
and was completed to the client’s exact specification
in just nine weeks.
Goals guarantee that every centre will not only have
changing rooms and showers, but a sports lounge
and multi-use function room as well, all of which
feature at Doncaster. The building is fitted with
climate control, intruder alarms and fire and
security systems.
The modern finish of the building is due to a combination of factors. Externally, the building is finished with micro rib cladding, with a porch feature
around the main entrance that provides additional usable space for the rooms behind. To maintain the external aesthetic, the building was designed
with the security measures for the doors and windows integrated into the walls, rather than the usual external wall fitting.
Goals’ branded graphics were used throughout the building both internally and externally to give the building it’s striking appearance.
To learn more about Wernick Buildings, please visit: www.wernick.co.uk
As seen on screen!
Portakabin, the UK’s leading supplier of modular buildings, has produced a
short film about how a highly complex, 4,200m2 ward and theatre building
was constructed at Royal Stoke University Hospital in less than four
months, to help meet the increasing demand for orthopaedic services.
The video, which can be viewed on their website, is a fly through the £13.5m
building showing the clean air theatres for all orthopaedic procedures,
recovery room, ward bays and single ensuite rooms. It features interviews
with a director of University of North Midlands NHS Trust and one of the
ward managers, providing a clinical perspective of the new building.
“We believe this project will really change perceptions about just what can
be achieved with modular construction – in an extremely short timescale
and on a highly constrained hospital site,” explained Robert Snook, Director
and General Manager of Portakabin Hire Division.
www.portanews.co.uk
30

Article >
World-class sixth form centre built using
offsite construction methods
The Sunday Times’ International Baccalaureate school of 2014 has been working with offsite construction specialists,
Actavo Building Solutions, to create a sixth form study centre to meet the school’s need for a world-class facility.
Tonbridge Grammar School in Deakin
Leas, Tonbridge, gained access to its
modular building after just 26 weeks
onsite, to meet the demand for pupil places
quickly and efficiently.
Designed to inspire and motivate pupils, Actavo
created the ‘IBarn’ – a brand-new, two-storey,
sixth form hub created to improve pupil
facilities and respond to rapid student growth.
The ground floor of the new sixth form includes
a café, collaborative learning areas and
changing rooms while the first floor comprises
an ICT suite alongside two large spaces that
can be used as classrooms, independent study,
seminar areas or opened up for lectures and
presentations.
The IBarn also frees vital space in the existing
sixth form accommodation to enhance student
development.
Matthew Goff, UK operations director at Actavo
| Building Solutions, said: “Perhaps the
popularity offsite construction has in the
education sector is due to its speed, versatility
and cost-effective nature.
“The competitive funding mechanisms and
demand for school places at Tonbridge
Grammar School meant tight deadlines
enhancing the school’s need for speed.”
As part of the tender process, Actavo | Building
Solutions developed a 3D animation to enable
32
the school to visualise how the new facility
would look once complete.
“As one of the UK’s top performing
international baccalaureate schools, it was
imperative we had a sixth form study centre
that met the needs of the internationally
minded curriculum. Actavo has helped us
achieve this with the creation of the ‘IBarn’,”
says Rosemary Joyce, Tonbridge Grammar
School’s Head Teacher.
“Actavo has provided us with a sixth form
facility that has the perfect balance between
form and function. The contemporary feel of
the ‘IBarn’, careful use of glass provides both
students and teaching staff with an open,
spacious and well ventilated space which
supports the focus on collaborative,
independent and reflective learning that is a
feature of our school.
“The study centre also provides the ideal
learning space for those preparing for
university and enabled refurbishment of the
vacated classrooms, facilitating more flexible
space for our talented musicians.
“As well as being architecturally attractive, our
new modular facility is an aspirational space to
both work and study. Proving the cost-effective
and speedy solutions offsite construction offers
in no way takes away from the quality of the
final building,” says Rosemary.
To view our exclusive walk-through and video
testimonial from Tonbridge Grammar’s head
teacher, Rosemary Joyce, please visit:
www.youtube.com/watch?v=1NVH7NLaOI0

FREE
DOWNLOAD
The
HA DLE
YDe sign
PRO
New
HAD
LEYDesignSuite
a wealth of
upgrades to ensure that planning
PRO
2.1 has
and specifying
any structural
engineeringg
FREE
DOWNLOAD
Project
Management
projects as well as archiving projects
to return to at a later stage.
SCI Assessed
Wind Wizard
Incorporates all roof types available
under
the Eurocode standards
including
barrel vault roofs.
Project
Optimiser
Import your data and De
signSuite
PRO
will output an optimised design from all
available systems including double spanning.
BS and
Eurocode
compliant
Appropriate load factor combinations
are detailed on printout reports.
Quick
Calculations
No need to open a new project every
time. Instead, run design sheets and
obtain
sizes instantly.
compatible software
To dow
wnload you
r
F
REE
SOFTWA
RE
visi
t
www.hadleygroup.com/s
oftware-dow
wnloads/ desi
gnsuite-pro.asp
x
T 0121
555 1340
E ask.bpd@hadleygroup.com
www.hadleygroup.com
/+HadleyGroupSmethwick
/ Hadley_Group /Hadley-Group

Article >
Timber driving its own design agenda
Technical Editor for MMC, Bruce Meechan, attends an evening seminar in the capital which brought together some
eminent advocates of wood as a material for major buildings.
> Metsä Wood represents hundreds of Finnish growers who ensure the sustainability of the
product range through their multi-generational management and replanting of the forests.
Despite having heard about Metsä
Wood's Plan B programme prior to
attending the debate sponsored by the
company at The University of the South Bank
some weeks back, I was not prepared for the
striking form and impressive size of the
engineered timber model in the foyer.
Replicating New York's iconic Empire State
Building.
There was no irate primate or circling bi-planes
to reprise the 1933 film or any of the remakes,
but the scene set out for the students,
architects and other professionals attending
did not require any added drama. Neither do
the other two structures, steeped in history,
that have also received the Plan B treatment
from a company renowned for its involvement
with countless contemporary buildings across
the construction sectors.
For while Metsä Wood has supplied its cross
laminated timber or CLT systems for schools,
nursing homes and other high specification
properties across the UK, its attempt to "reimagine"
projects prominent in history, from a
timber perspective - have focused on the
Colosseum in Rome and the German Reichstag,
as well as the 102 storey, 1,454 foot tall office
block which still stands out on the New York
skyline today. Effectively, what the Finnish
timber importer has managed to show is that
any of the world's most striking structures -
even those of massive scale - could feasibly be
built today using advanced timber technology.
Not simply replicating them, but actually
improving on them in a variety of ways, offering
benefits for both the builders and the
occupants or users.
We will return to the particulars of the Plan B
project later, but it was the shared agenda of
the architects assembled at the LSBU building
which is of even greater relevance to our
readership. Representing as they do some of
the most adventurous design practices active in
the UK.
All of them have been instrumental in
delivering successful projects in either
engineered timber, or what most in the industry
would regard as 'stick-build' - but it was a
remark by Andrew Waugh whose practice,
Waugh Thistleton designed Murray Grove,
which stood out for me. He asserted that:
"Timber will generate its own architecture!"
34

Amongst the benefits he highlighted for the
landmark social housing scheme and other
predominantly timber based builds were the
lightness, speed of erection and the reduced
reliance on heavy equipment. Andrew Waugh
commented as he ran through his slides that
"These are robust buildings." However he
explained how they went together without the
use of tower cranes, while the erectors mainly
made use of cordless screwdrivers or other
hand-held tools for assembling the
components.
Furthermore, while nail guns tended to be the
noisiest feature of the construction cycle, the
acoustic performance of the finished structure
was addressed using a variety of insulation
materials and a pumped screed flooring
system. The latter feature also offers a ready
answer to timber framing's widely recognized
lack of thermal mass. In fact such screeds can
both provide a feeling of substance under foot -
even accommodating disability buggies indoors
- and create a heat sink to flatten out spikes
from the daily heating and cooling cycle.
For his contribution to the evening's
proceedings, Metsä Wood's Head of Technical,
Engineering and Design, Frank Werling, opted
not to expand on the details of the Plan B
process, but to explain some of the potentials
for the manufacturer's extensive product
range; including Kerto.
He explained how Kerto Q offers different
properties to Kerto S through having some 20
per cent of the wood grains orientated
crossways in the manner of plywood. The
sophistication of the production processes not
only enable the characteristics of the timber
elements to be fine-tuned, but these can of
course be reassembled into I-beams or box
sections to allow widely differing load
conditions to be accommodated.
For its analysis of Rome’s ancient gladiatorial
arena, Metsä Wood not only made use of
physical measurements and satellite
photography, but also assumptions about the
live loads which would have been imposed by
spectators and lions alike. With these then
"At 190 metres by 158 metres, the
Colosseum is a huge building –
almost three times the size of an
average sports arena. Initially, I
thought that wooden construction
to such an extent wouldn't be
feasible in reality. As the project
proceeded, I changed my mind. It
would not only be possible, but
easy as well."
Architect Antti Laiho
available to input into the company’s
sophisticated design software, it was found that
LVL or laminated veneered lumber, could
indeed sustain the loadings.
The celebrated architect Antti Laiho duly
worked with Metsä Wood’s structural engineer,
Jussi Bjorman, to produce a new structural
solution employing various LVL products in
order to recreate the Colosseum’s distinctive
elliptical form. Significantly, the LVL structure
was not only shown to offer a lower weight and
quicker erection, but also 12% additional space
in the vaults below the seating arena. This
could now potentially accommodate VIP
facilities and retail outlets. It is also certain that
health and safety standards would be
unrecognizable from the workplace of 72 AD.
Antti Laiho asserted: "At 190 metres by 158
metres, the Colosseum is a huge building –
almost three times the size of an average
sports arena. Initially, I thought that wooden
construction to such an extent wouldn't be
feasible in reality. As the project proceeded, I
changed my mind. It would not only be possible,
but easy as well."
Offering a perspective from the opposite end of
the timber engineering spectrum, John Broome
- principal of John Broome Architects - posed
the question to the audience of what a
sustainable neighbourhood might look like?
And having been closely involved in guiding a
genuine self-build project in the London
Borough of Lewisham, where residents were
hands-on with a basic timber frame build, he
suggested that: "Over the years we have been
building with panel construction and ‘poles'
(apparently whole sections of tree trunks) I
think this is a hint about how one might think
about having a building culture which is
accessible to people at large; and based on
functional ideas rather than stylistic ones -
based on needs and economies of scale as well
as environmental performance and variety of
use."
The impression that everyone will have left the
South Bank with after the seminar is that
timber is as versatile in construction as the
potato is in cooking.
MMC May 2016 35

Training, Tools & Equipment >
Equipping the next generation for
increasing offsite demand
Offsite construction has actually been around for decades; however, following the surge in demand for homes in late
2013 and early 2014 and a subsequent decrease in availability of traditional materials such as bricks, it is only now
that its benefits of offsite are truly being recognised.
The prime benefit of modular building
and offsite construction is that it
provides specifiers with programme
certainty and quality though simplification of
site operations and reduced weather
dependencies due to the controlled factorybased
assembly process. The ancillary benefit
of this is that buildings delivered through
offsite construction offer enhanced
specification standards and build-quality
which reduces occupancy costs related to
energy use, defects and repairs.
The Offsite Management School is one such
organisation that has risen to the challenge.
Launched in 2015, they now have a consortium
of partners, including Skanska, Carillion, Laing
O’Rourke, Costain, United Utilities, Saint
Gobain, Prater, and McAvoy alongside leading
knowledge based organisations, such as BRE,
Total Flow, Exelin, BuildOffsite and CITB.
Offsite Management’s Self-Assessment Tool is
one such option that has been designed to help
you assess your company's current
industrialisation strengths and to identify the
areas in which you can develop your
competence.
Continues on page 38...
Training
Ministers have recently announced that they
want the construction industry to focus efforts
on attracting, developing and retaining home
grown talent into the industry and remove
barriers currently preventing more young
people from entering the sector.
This involves looking at how companies recruit
and train, but also at how adopting modern
technologies and methods could help to keep
our sector interesting, up-to-date and attractive
to the next generation of budding construction
professionals.
36

SENCO HAS OFF-SITE MANUFACTURING COVERED
HIGH LOAD TOOLS
HIGH LOAD
STAPLER
HIGH LOAD
COILNAILER
SMART LOAD
STAPLER
SMART SERIES
SMART SERIES
COILNAILER
SMART SERIES DURASPIN
HIGH LOAD TOOLS
The Senco High load tools are a range of
nailing and stapling machines with high
capacity to the changing demands of
modern, automated timber framing
technology. With modular compact design
the High Load tools provide increased
production with less re-loading, reducing
the tool down time.
SMART SERIES
The Senco Smart Bridge has been
developed for entry level automation of
nailing, stapling and screwing
prefabricated panel assembly. This highly
flexible Smart bridge will help
manufactures to increase capacity and
quality without increasing the manpower.
Remote firing of the Smart Bridge tools
provides a safer working environment and
reduces the strain on the operator.
SENCO XTREMEPRO TOOLING RANGE
The Xtremepro series provide
Xtremequality for industrial
manufacturing applications, elite tools
built with the highest quality for 24/7 use
in the toughest industrial environments.
These tools feature upgraded internal
designs for maximum durability across a
wide range of fastening systems. Senco’s
Xtremepro range provides Performance,
Power and productivity.
www.senco.eu
Poppers Senco UK Ltd, 630 Europa Boulevard, Warrington, WA5 7YH
MAKING HARD WORK EASIER

Training, Tools & Equipment >
...continued from page 36
You can then work your way up from member
through to gold status by engaging in the
School, including viewing resources, completing
e-learning modules and attending events.
Speaking to MMC Magazine, Founding Director
& CEO of Construction consultancy Cast, Mark
Farmer said "Our industry is in chronic need for
modernisation. Low levels of productivity, a
lack of skilled tradesmen, an ageing workforce
and problems attracting new people into the
industry add up to a dangerous cocktail that
does not bode well for the future of
construction. That is why the need for us to
change how we design, procure and build has
never been so important. We need to accelerate
a move to advanced manufacturing techniques
which are less labour intensive and which offer
high levels of predictability for clients. The
need for a much wider adoption of BIM is
central to this move as digital engineering lies
at the heart of modernising our approaches.
This in turn changes the skills mix required in
the future, taking pressure off the need for
traditional tradesmen and creating an
attractive array of multi-skilled and digital
technician career propositions for the next
generation. The urgency for change has never
been greater, the question is whether industry
will seize the opportunity."
Equipment
With recent growth in
the offsite
construction sector,
those working within
the tools and
equipment sector are
also seeing an
increase in the use of
their products and
systems in a
multitude of projects
nationwide. This in
turn results in an
increasing need to
design and innovate
as an industry.
Managing Director of Jackpad Ltd, Kris
Cartwright spoke to MMC Magazine about how
they are continuing to evolve and innovate in
order to meet demand. Kris said “The advances
in offsite construction over the last few years
have been immense, with the addition of new
technology fuelling this growth. At Jackpad, we
have been supplying portable foundation
systems for modular buildings for the last
sixteen years, it’s a simple idea that means no
excavation or concrete foundations are
required.
Jackpads are perfect for the offsite sector with
the system having LABC Approval, the
Jackpads are laid out quickly and efficiently
ready for the modular building or pod to be
craned into place. It has taken some time for us
to spread the word, but our portable
foundation system has now been used for a
myriad of major projects like the Olympic
Games and the Commonwealth Games as well
as healthcare and education projects
throughout the UK.”
Needless to say, if we are to harness the true
potential of the recent uptake in modular, we
need to focus heavily on training an existing
workforce whilst also attracting new talent
into our midst. It is also imperative that we
continue to develop every tool in our arsenal
to ensure we keep up with the market going
forward.
38

Performance. Power. Productivity.
As a professional in in-plant manufacturing or the
construction market you want to work with the best
tools available. Senco is the brand for you. As one of the
best known brands in the world of fastening technology Senco
produces a wide range of pneumatic, electric, gas, cordless
pneumatic and battery powered tools that matches your needs.
Senco’s DuraSpin collated screw system and the cordless
Fusion tools can offer you unique technological advantages and
together with Senco pneumatic tools you can use them in an
extensive range of construction and in-plant manufacturing
industries such as the furniture, bedding, caravans & holiday
homes, timber & steel frame buildings, pallets, packing cases
and automotive.
www.senco.eu
You can use Senco fastening tools for every application. To make a
clear difference between the performance of the tools Senco has
divided them up into product lines including the following series:
When you work in the toughest industrial environment you need a tool with
extreme quality. Senco tools in the XtremePro series are built with the
highest quality and can be used for 24/7.
If you need a professional tool for lower volume applications that still
provides a high level of performance and reliability the Senco ProSeries will
provide the perfect solution for all your fastener application needs.
When you work in the pallet or packaging industry you need tools that are
reliable and have low maintenance. Senco has designed tools specifically
for this industry. The tools are perfectly balanced and very powerful, which
enables long-term use.
When you need a stapler or nailer occasionally for professional use in a
home or garden application, than a tool of the SemiPro serie is just the tool
for you. Senco quality for the low volume user.
When you have a high quality tool, you also want a high quality compressor.
Senco offers a complete range of compressors for every application. The
compressors fit especially well with Senco tools, but can be used
everywhere.
Do you want a cordless nailer, but with pneumatic power? Senco nailers
with Fusion Technology use compressed air that is permanently sealed in
the tool’s self-contained, built-in cylinder to unleash a shot of pure portable
pneumatic power every time you pull the trigger.
With the Senco DuraSpin collated screw fastening systems you can screw
50% faster than with manual screwing. The Senco DuraSpin tools are the
best choice for your demanding drywall and wood fastening applications.
No matter where – or what – your next job is, if it demands collated nails,
staples or screws that drive easily and completely, with fewer jams – and
meet the construction industry’s performance codes - demand Senco
fasteners.
: Smart Series Duraspin
Senco accessories such as air hoses, plugs and couplers etc offer
you the perfect connection between tools and compressors.
MMC May 2016 39

Vision London >
Optima from Profile 22: future-proof
high performance windows
Months of rumours and speculation are
now at an end as Profile 22 launches
not one but two of the industry’s
most eagerly awaited window and door
systems. Hailed as the biggest new product
introduction in the window industry for a
decade, Profile 22 has unveiled Optima,
developed to be the most advanced products
of their type available in the UK today.
Developed specifically with commercial sectors
in mind, and backed by the Profile 22 Approved
Window Contractors scheme, Optima offers a
compelling choice for the professional specifier.
Behind this launch is a radical rethink of each
of the key processes in the production of a
window and door system for the 21st Century:
extrusion processes that ensure superb quality
and consistency whilst protecting the
environment through reduced energy and
ecological impact and products that easily
satisfy current technical and aesthetic
demands by anticipating those of many years
ahead.
The two product streams are
characterised by the Optima
Chamfered System and the Optima
Sculptured System, from which a
large number of options are
available including a brand new
Flush Casement to compete in the
burgeoning ‘heritage’ flush sash
timber replacement sector.
In basis the systems offer a 6 chamber outer
frame (up to 8 with RCM inserts) and a 5
chamber sash (6 with RCM), structures that
provide optimal thermal performance and
rigidity with the capability of U values as low as
0.8 W/m2K with appropriate Argon filled IGUs.
Around these basic structures will be the
widest range of ancillaries and add-ons of any
system on the market to allow the production
of windows in every style, for every property
type. Important niche products such as a fully
reversible window; a vertical sliding sash; flush
tilt & turn; a flush casement; composite door;
french door sets; and a patio door may be
See us at
VISION 2016,
Earl’s Court
on 7 & 8 June
Stand 65
manufactured by combining existing profiles
with the Optima suite. Performance is to A++
Window Energy Rating.
The Profile 22 system that Optima replaces
enjoyed huge popularity for its aesthetics and
Optima retains a close similarity, but with a
larger rebate and stylish slim upstand. The
distinctiveness enjoyed by Profile 22 over other
systems will therefore continue.
The real difference however is in the details:
the system is designed with a high performance
centre seal option for improved weather and
thermal performance, features that are unique
to Optima amongst UK systems; deeper
drainage channels further improve water
egress and contribute towards weather
performance.
Optima has been designed to offer the widest
choice of glazing options on the market
including 24 and 28mm double and 36, 40 and
44mm triple glazed units. Bead location has
been fully researched with the result that
glazing clips are unnecessary to
pass security tests and are
future-proof against proposed and
anticipated enhancements to
PAS24.
The systems have been awarded
the British Standard Kitemark
which includes testing to BS6375
parts 1, 2 & 3, Performance of windows
and doors in addition to testing in relation
to PAS24:2016 enhanced security performance
requirements for doorsets and windows in the
UK. Both standards are the latest to be
published and allow specifiers to assess Optima
against the most exacting UK standards
currently available.
Products are also manufactured under
Environmental and Health & Safety standards
BS EN ISO 14001 and BS EN ISO 18001
respectively and BES6001 to ensure
Responsible Sourcing of Construction Products.
The Optima systems far surpass UK and EU
Building Regulations and PAS24, and have the
highly accredited Secured by Design approval.
In short Optima is the most accredited window
system available in the UK market today.
The increased demand in the window market
for colour and woodgrain has been
acknowledged with an increased stock and fast
turnaround of special colour options. The
Optima foil offer is superior to that of any other
systems supplier boasting 28 colour options.
The range of greys competes well with
aluminium products.
Andrew Reid, Commercial Sales Director of
Profile 22 says: “We wanted the new window
systems to be the best in the market and
represent innovative design and exceptional
thermal performance. We designed the new
products around the needs of the specifier for
slim, modern and stylish aesthetics, whilst
offering the most technologically advanced
product features and performance capabilities
to future-proof our product range in meeting
future Building Regulations.
“To achieve this we have invested in the most
advanced extrusion systems available today.
This investment ensures consistently excellent
window and door profile quality whilst also
significantly reducing the environmental impact
of the production process. This is a key element
in the specification of modern window and door
products,” added Andrew.
“Specifiers can include Optima knowing that
they are choosing the most advanced window
and door products available in the UK today
with key benefits of exceptional thermal
performance, reduced maintenance schedules
and improved durability. Their clients will also
enjoy the benefits of excellent design, greater
comfort levels and security as well as reduced
heating bills for tenants and homeowners
alike.”
Those wanting to appreciate Optima are
encouraged to visit the Profile 22 microsite
www.profile22.co.uk/optima, the showroom in
Telford or at the Building Centre, London.
www.profile22.co.uk
40

Vision London >
G-frame engineered timber & hybrid structures
G-frame Structures specialises in the design,
supply and installation of engineered
timber and hybrid structures. A
designer of bespoke solutions, G-frame
Structures offers a direct route to a complete
hybrid package working with a palette that
includes Cross Laminated Timber, Glulam,
Laminated Veneered Lumber. We are also able to
meet your other structural solutions using more
standard construction materials through our sister
company Murform Ltd.
Involve us early in the design stages and we’ll help you to
make savings from the outset and deliver your project
ahead of programme with safety first and inside budget. We
can also advise and help you to interface with a range of
other systems, we are able to design and install timber
cladding panels and insulated render as part of our water
proof envelope package.
Known by our partners and clients for our hands-on
approach to problem solving and fast, efficient delivery, the
G-frame team brings a high degree of multi-disciplinary
expertise and a commitment to building lasting
relationships which leads to repeat business. We provide solutions across the range of building types including social and private residential,
education, public access and workspace. Recent projects include the new Moneypenny HQ in Wrexham by AEW Architects, 150 London Road by
Stephen Davy Peter Smith Architects and Graveney School 6th Form Block by Urban Projects Bureau which has recently won two awards at the 2016
RIBA London Awards.
All wood products are PEFC or FSC certified.
G-frame
Structures will be
at VISION 2016 in
Earl’s Court on 7 & 8
June – come and
see us on stand
105
For more information please email Joe Hall at j.hall@g-frame.co.uk, call us on 01525 288022 or visit www.g-frame.co.uk
Recticel Insulation set to showcase new feel-good
systems at Vision
A new philosophy and a new product will headline on Recticel’s Vision stand.
Leading PIR manufacturer Recticel Insulation (stand 45)
is launching its new “Feel good inside” philosophy and
debuting a self-supporting room-in-a-roof system for
pitched roofs at this year’s Vision built environment
exhibition for architects, specifiers, clients and suppliers
(June 7-8, Olympia).
The next-generation product, L-Ments, comprises roofing
underlay, counter battens and integral structural timber in one
PIR insulation panel as a single lightweight cost-effective
modular roofing element, making it exceptionally quick and
easy to install.
The innovation new system enables specifiers and contractors
to design and build roofs without the risk of thermal bridging,
providing them with a future-proof solution thanks to its highperformance
insulation core.
Using L-Ments in conjunction with Recticel’s full fill cavity wall
insulation Eurowall + provides specifiers and contractors with a holistic building solution for the
complete building envelope that showcases this “feel good inside” approach.
It also showcases Recticel’s fabric first approach to build as well as Modern Methods of
Construction via the use of fewer materials and speedier installation.
Representatives from Recticel’s technical department will man the stand to answer technical
questions, advise on building materials, installation, prices, grants and bespoke solutions for
specific needs.
Recticel Insulation
will be at VISION
2016 in Earl’s Court
on 7 & 8 June –
come and see us on
stand 45
42

Building using
our high
thermal performance e, airtight, closed panel
timber frame system ms for floors, walls &
roofs minimises the requirement for mirco
renewable technolog gies by embracing
‘Fabric First’ principles.
AIRTIGHTNESS
THERMAL
PERFORMANCE
ENERGY
EFFICIENCY
SPEED OF
CONSTRUCTION
Cumbernauld
Inverurie
Dundee
Inverness
Paignton
West Sussex
01236 861200
01467 624440
01382 561772
01463 717328
01803 267680
01273 831896
www.scotframe.co.uk
Let Scotframe
thermally engineer
a solution fo or you.
MMC May 2016 43

Product News >
Maximum benefits from MAXX
With the new additions to the MAXX family, Delta Membrane
Systems offer a range of products that bring to the market the
most secure basement pumping systems for type C (cavity drain)
waterproofing.
Included in the range
are the DMS270 for
ground water and
surface water
applications, and the
DMS269 for foul
water use. Also
available is the
PowerMAXX which
can run a standard
V3 pump without
mains power for up
to four days,
depending on the
number of cycles per
hour. It can sit in
standby mode for
over three weeks, and is virtually inaudible. Completing the line‐up
is the MessageMAXX which, combined with AlertMAXX, gives
remote monitoring when residents are away from the property.
Messages are sent using GSM technology, usually in text format.
All of these models are ideally suited to the range of pumps
offered by Delta Membrane Systems, making the company a ‘one
stop shop’ for pumping packages.
www.deltamembranes.com.
Offsite construction allows
powder coating benefits
Changes in construction methods and preferences influence the
range of other techniques that can be introduced into a project,
such as metal finishing. Steel balconies and balustrade are a
good example, as their construction has changed significantly
over the past twenty years. Balconies and balustrade used to be
fabricated and painted on site before being attached to the
building. The next stage in balcony evolution was to fabricate and
paint components off-site and erect on site. Nowadays, entire
balconies and balustrade are fabricated, assembled and painted
off site as manufacturers add more storage space to their
facilities and construction sites have correspondingly less room.
The finished balcony is transported and bolted to the building as a
complete unit.
Offsite construction means that today's steel structures can
benefit from factory applied high performance powder coatings.
Powdertech's Corby plant has a capacity of 1000kg uniformly
distributed over a length of 6500mm so can easily handle large
items. A powder coated finish offers excellent protection and
durability of up to 30 years, far greater than that afforded by air
drying paints. Environmental problems associated with using air
drying paints, inconsistency of application techniques on site and
potentially expensive delays due to adverse weather conditions
are avoided.
Pre-fab Armourdek roof panel
launched
The UK’s only
PVC and TPE
single ply
manufacturer, IKO
Polymeric, has
officially
launched
Armourdek, a
pre-fabricated
long spanning
roof deck for fast
track installation.
Factory finished with BBA certified Armourplan PVC or
Spectraplan TPE single ply membrane, Armourdek is ideal for
high performance waterproof roofing. With excellent thermal and
acoustic properties it offers superb air tightness and its ‘zero
waste’ manufacturing approach means no material used goes to
landfill. It can be used in all construction sectors and is suitable
for steel, concrete and timber frames.
As the single ply membrane is applied to Armourdek in the
factory the panel can simply be delivered and craned into place
on site, minimising the need to install a separate roofing system.
This saves a significant amount of time – and with available sizes
up to 12m x 4m, installation can be as quick as 1,000m2 per day!
http://www.ikogroup.co.uk/Products/Flat-
Roofing/Polymeric-Single-Ply-Systems/Armourdek-Compo
site-Roofing/
: Nowadays, entire balconies and balustrade are
fabricated, assembled and painted off site as
manufacturers add more storage space to their facilities
and construction sites have correspondingly less room.
Interestingly balconies and balustrade are increasingly being used
as part of the overall design of a building. Powder coatings in
their many shades, tones and textures can enhance these
structures and their longevity means that the building will retain
its appearance for many years.
For more information on powder coating steel structures please contact
Powdertech on pcl@powdertech.co.uk.
44

“
https://offsiteshow.co.uk
• On course for a sell-out after great launch in 2015.
• The UK’s most prestigious Offsite event.
• Top Class Seminar program in 2 in-hall theatres.
• LIVE in-hall Demos and Masterclasses - all FREE!
• FREE entry to the show and all seminars!
An excellent show. I heard nothing but praise
from both exhibitors and attendees for both
concept and delivery.
”
Prof. Nick Whitehouse MBE
Oxford Brookes University
The Offsite showcase - the future of construction

Article >
Shackerley cladding is right on track
at Newbury Racecourse
Ventilated façade specialist Shackerley has supplied over 3000m 2 of white SureClad ® ceramic granite
cladding for three luxurious apartment complexes at one of the UK’s premier racecourses.
Carruthers Court, Chatham House and
Bregawn House have been developed
by David Wilson Homes in partnership
with Newbury Racecourse. Two of the
buildings directly overlook the racetrack,
offering spectacular panoramic views from
spacious tiered balconies.
The apartments were the first to be completed
on land adjacent to the racecourse, as part of a
ten-year homebuilding programme.
Shackerley’s cladding has provided a crisp and
contemporary aesthetic and maintained design
continuity with the neighbouring grandstand.
Whilst Tolent Construction and Ian Springford
Architects delivered the buildings, Gloucesterbased
Roberts Limbrick Architects specified
Shackerley’s SureClad ® façade system in the
designs that went to tender.
“We particularly wanted to reflect the sharp
and angular, tiered look of the grandstand,”
said Roberts Limbrick Associate Andrew Smith.
“We were looking for a premium quality
material with very hardwearing, durable
properties that would contrast with the red
brickwork and deliver that typical vernacular
styling. Shackerley’s SureClad ® solution
provided everything our client was looking for –
a fantastic low maintenance façade material,
and flexible installation systems to
accommodate all requirements. Nothing had to
be compromised.”
Daniel Pavely, NRC Director at David Wilson
Homes, agreed: “This is a unique development.
We’re not just providing living space, but a
whole lifestyle. It was important that these
blocks not only echoed the landscape and
surrounding architecture, but also boasted a
premium quality finish. Without doubt,
Shackerley’s product has helped us to achieve
our vision.”
Shackerley’s most economic 1200 x 600mm
façade panel format was used with a SureClad ®
Access system to clad balcony partitions. To
reduce installation time and costs when
cladding the balcony edges, Shackerley worked
with the project team to design a bracketed
beam unit comprising fascia, soffit and cill
components which was prefabricated and
delivered to site, ready to install as part of a
SureClad ® Hang On system. Tony Blake,
Commercial Director at Speedclad, commented:
“This greatly reduced the amount of framing
needed, and our overall installation time. This
project has helped to reinforce our view that
Shackerley offers a very impressive high quality
product and good value for money.”
Tel: 0800 783 0391, email,
info@shackerley.com, www.shackerley.com
46

Revolutionis
e
your
project
delivery
Skanska Fabrications can improve quality, minimise
cost and reduce installation time on your project by
manufacturing mechanical, electrical and plumbing
system elements off-site.
Our projects include commercial buildings such as
30 St Mary Axe (the Gherkin), high quality residential
apartments, schools and healthcare facilities,
plus many more.
To find out how you could save time and money,
while improving on-site safety, contact us on
01753 554215 or srw.enquiries@skanska.co.uk.
www.skanska.co.uk