MMC 5541 48 Nov'15 cc
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Offsite given wings<br />
Juliet Woodcock looks at a new<br />
concept surrounding modern<br />
methods of construction.<br />
MODERN METHODS OF CONSTRUCTION<br />
> issue <strong>5541</strong> | Nov | 2015<br />
‘Traditional’ approach to island<br />
PassivHaus properties<br />
<strong>MMC</strong> Magazine’s Bruce Meechan<br />
reports on a substantial low energy<br />
development by one of the southeast<br />
of England’s largest<br />
housing associations.<br />
Glazing systems specialist Kawneer expands its curtain wall portfolio > See page 12...
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CONTENTS<br />
issue <strong>5541</strong> | Nov | 2015<br />
Dear Reader,<br />
We often see parallels drawn between construction<br />
and the automotive industry, especially when it<br />
comes to mimicking the car-makers’ levels of<br />
efficiency and low waste through the adoption of<br />
“Modern Methods” -but a very uncomfortable<br />
analogy has emerged since our last edition.<br />
VW has been heavily criticized after US authorities<br />
exposed its use of ‘Defeat Software” to conceal the<br />
true levels of pollution emitted by millions of the<br />
company’s diesel vehicles, landing the company<br />
with massive compensation claims from<br />
purchasers who rightly feel duped, and slashing its<br />
stock market value.<br />
I often buy shares when a blue chip company takes<br />
such a hit, but this time I fear there is worse news<br />
to come, while it also makes me ponder the<br />
increasing amount of reports I am seeing about<br />
new properties drastically underperforming in<br />
terms of their energy usage. It seems in such areas<br />
as cold-bridging and preventing air leakage, our<br />
housebuilders are struggling to get things right in<br />
practice.<br />
We are a long way at present from seeing<br />
disgruntled home-buyers starting class actions in<br />
the courts, but some kind of fiscal punishment<br />
from Government is much easier to imagine.<br />
Almost certainly, increased use of offsite<br />
technologies will help close the performance gap<br />
between design and o<strong>cc</strong>upant consumption.<br />
Meanwhile, with 38 of Britain’s 43 air quality zones<br />
exceeding EU safety limits for nitrogen dioxide, and<br />
air pollution estimated to be responsible for<br />
28,000 deaths a year, perhaps we should be<br />
making more use of products such as the coating<br />
to roof tiles which digests NOx, and also try to<br />
develop new homes in localities that will minimize<br />
vehicle usage.<br />
Yours sincerely<br />
Bruce Meechan<br />
Editorial Enquiries Tel: 01827 301190<br />
Press Releases, Advertising, Production,<br />
Design & Circulation Enquiries<br />
Tel: 01827 301198<br />
Features Editor Bruce Meechan<br />
News Editor Juliet Woodcock<br />
Press Co-ordinator Gemma Spilsbury<br />
press@wavcoms.co.uk<br />
Advertising Kevin Edgeworth<br />
kedge@wavcoms.co.uk<br />
Design Ellie Rich and Di Smith<br />
Circulation<br />
circulation@wavcoms.co.uk<br />
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agents.<br />
Waverley Communications Ltd.<br />
Waverley House, 11 Galena Close,<br />
Amington Heights, Amington Industrial Estate,<br />
Tamworth, Staffordshire. B77 4AS.<br />
10 Offsite given wings<br />
Juliet Woodcock looks at a new concept<br />
surrounding modern methods of construction.<br />
12 New unitised curtain walling<br />
launched by Kawneer<br />
Glazing systems specialist Kawneer expands<br />
its curtain wall portfolio.<br />
32 ‘Traditional’ approach to island<br />
PassivHaus properties<br />
<strong>MMC</strong> Magazine’s Bruce Meechan reports on a<br />
substantial low energy development by one of<br />
the south-east of England’s largest housing<br />
associations.<br />
38 Shackerley’s engineered stone<br />
façades shape up beautifully<br />
Shackerley has demonstrated the<br />
extraordinary design potential and versatility<br />
of its Sureclad ® ventilated cladding offer by<br />
supplying an innovative engineered stone<br />
façade system for a challenging installation at<br />
Kew Bridge West.<br />
< Front cover<br />
18 STEICO – natural products for<br />
healthy buildings<br />
STEICO products are innovative building<br />
materials that offer long-term performance,<br />
increase the comfort of living and help to<br />
visibly increase the energy efficiency in<br />
buildings.<br />
32 Building fabric in the firing line<br />
Technical Editor Bruce Meechan reports from<br />
the Inmarsat Centre in London about a wide<br />
ranging conference staged there on November<br />
18th.<br />
Leading architectural aluminium systems supplier<br />
Kawneer has brought 50 years’ expertise to the<br />
launch of a new fast-track dry-glazed unitised or<br />
off-site curtain walling system that is an exemplar<br />
of Modern Methods of Construction.<br />
See page 12 for more info...<br />
www.kawneer.co.uk<br />
10<br />
<strong>MMC</strong> Nov 2015 3
NEWS<br />
Smart Cities, Big Data &<br />
the Built Environment<br />
The School of the Built Environment (in<br />
partnership with School of Real Estate<br />
and Planning) has recently won a<br />
prestigious grant from the RICS Research<br />
Trust in its special 'big data' call. The<br />
research (which is led by Professor Tim Dixon<br />
with Professor Martin Sexton and Dr Jorn<br />
Van de Wetering) will examine the drivers and<br />
barriers for big data platforms at city level in<br />
the UK.<br />
The smart city model provides huge<br />
opportunities to create added business and<br />
economic value from the integration of big<br />
data, covering many areas of the built<br />
environment. These include data relating to<br />
buildings, land use, planning, environmental<br />
data, health, economy, and energy.<br />
“More offsite” says<br />
build systems<br />
manufacturer<br />
The UK construction industry will benefit<br />
from increased opportunities for<br />
professionals to develop their<br />
knowledge of offsite construction, a<strong>cc</strong>ording to<br />
John Smith of Stewart Milne Timber Systems.<br />
Head of Technical, John Smith, believes that as<br />
more professionals are given the opportunity<br />
to understand offsite construction’s<br />
advantages and the latest developments which<br />
might assist them, the industry as a whole will<br />
benefit.<br />
To contribute to this, Stewart Milne Timber<br />
Systems offered a CPD session at its Witney<br />
facility in September, which was hosted in<br />
partnership with the Structural Timber<br />
Association (STA) and was free of charge to<br />
housebuilders, quantity surveyors,<br />
construction managers, directors, and<br />
affordable housing providers. It carries official<br />
CPD-a<strong>cc</strong>reditation for Royal Institute of British<br />
Architects (RIBA) members and included UK<br />
building industry “needs more offsite<br />
construction CPD” says the leading build<br />
systems manufacturer.<br />
John Smith said: “We believe that offsite<br />
construction has an important part to play in<br />
shaping the UK’s construction industry in<br />
coming years, and will continue offering CPD<br />
opportunities such as this in future. We expect<br />
to see similar offers from the rest of the<br />
industry as more professionals begin to<br />
employ offsite construction methods.”<br />
Researcher looking for ways to build a million new<br />
homes<br />
ALoughborough University researcher, engineer Ron Lang, hopes his study into house<br />
construction could revolutionize the way homes are built in the UK. His research is in the<br />
final stages of a four-year project looking at alternative methods of constructing<br />
housing.<br />
Whilst many researchers continue to look for ways to move the production of houses away from<br />
site and into factories, Ron believes there is a solid case for developing traditional methods.<br />
To identify alternative construction methods, six full-scale test walls with varying specifications<br />
have been constructed at Loughborough University’s School of Civil and Building Engineering.<br />
The walls were constructed under site conditions to allow Ron and his team to assess the build<br />
process for each alternative solution.<br />
He said: “If we can simplify on-site construction, we can improve the quality of our homes, speed<br />
up the home-building process and help the government to achieve its target of one million new<br />
homes in England by 2020.”<br />
The project is jointly funded by the Engineering and Physical Sciences Research Council (EPSRC)<br />
and Leicestershire-based company, Aggregate Industries (part of the LafargeHolcim group).<br />
Industry support has also been received from Gusto Construction, Tarmac Building Products,<br />
Forterra (formerly Hanson Building Products) and Low Therm Solutions.<br />
Builders bin the pub<br />
Forget the pub, white van men are more likely to be found in the gym working out than drinking<br />
pints, a<strong>cc</strong>ording to a new survey.<br />
A study of 1,000 tradespeople* by IronmongeryDirect, online and mail order supplier of ironmongery<br />
products to the trade, found that a substantial 69% of tradesmen don’t go to the pub that often, and 10%<br />
never go. 17% go once or twice a week but only 2% go most days and the same percentage every day.<br />
However, 32% claimed that they regularly go to the gym and exercise, and 50% said they are watching<br />
their weight. 13% are currently on the Atkins diet, 13% are using Slimming World, 11% use Herbalife, 8%<br />
are on the 5:2 diet and 5% are with Weight Watchers.<br />
The survey was conducted as part of IronmongeryDirect’s ‘The real white van man revealed’ campaign,<br />
which aims to shed the stereotypes often associated with tradespeople.<br />
Work starts on new a<strong>cc</strong>ommodation for Army<br />
medics<br />
The Defence Infrastructure Organization (DIO) has started work on new en-suite single<br />
living a<strong>cc</strong>ommodation for Army medics at Keogh Barracks in Ash Vale, Surrey.<br />
The £3.9 million project is being carried out in partnership with modular construction<br />
specialists, Rollalong, and is planned to complete in summer next year.<br />
Once finished, the 70-bed facility will conclude the modernization of junior ranks<br />
a<strong>cc</strong>ommodation at the barracks. It follows recent works to convert existing a<strong>cc</strong>ommodation<br />
from multi-o<strong>cc</strong>upancy rooms to single rooms.<br />
It’s part of a wider £50 million redevelopment project to enhance the barracks over four years<br />
for its new o<strong>cc</strong>upants.<br />
4 Armoured Medical Regiment (4AMR) relocated to the site earlier this year from nearby<br />
Normandy Barracks in Aldershot, while22 Field Hospital and Ministry of Defence Hospital Unit<br />
(Frimley Park) are scheduled to move to Keogh Barracks starting next year, following further<br />
refurbishment and new buildings.<br />
Over £30 million of remaining major works will follow with procurement starting shortly to<br />
provide a new Sergeants’ Mess, stores, vehicle workshops and an armoury.<br />
The redevelopment of Keogh Barracks is part of the Army Basing Programme (ABP), which is<br />
providing the facilities the Army needs to live, work and train in the UK as it returns from<br />
Germany, relocates bases across the UK and restructures under Army 2020. This year more<br />
than 5,000 Service personnel have returned to the UK from Germany and 1,800 have relocated<br />
within the UK as part of the programme.<br />
4
Addressing poor air<br />
quality<br />
Research shows that modern airtight<br />
homes are more likely to<br />
suffer from poor indoor air quality<br />
and leads to change in Scottish building<br />
regulations.<br />
After years of research into poor indoor air<br />
quality in modern homes, a team of British<br />
architects have been recognized by the<br />
Chartered Institute of Building Services<br />
Engineers. Dr Stirling Howieson, University<br />
of Strathclyde, Dr Tim Sharpe, Mackintosh<br />
Environmental Architecture Research Unit<br />
and Paul Farren, ASSIST Design Ltd. were<br />
presented with the Napier Shaw Bronze<br />
Medal award on 9th October 2015 at the<br />
annual CIBSE President’s Award Dinner for<br />
their 2014 research paper, “Build Tight,<br />
Ventilating Right?” which demonstrated<br />
that standard air tightness levels within<br />
houses constructed to current regulations<br />
are likely to result in poor indoor air<br />
quality.<br />
Further research by the team, undertaken<br />
on behalf of the Scottish government, has<br />
led to a change in the Building Standards.<br />
From October 2015 all new homes in<br />
Scotland are to be fitted with bedroom<br />
CO2 monitors.<br />
Finalists announced<br />
for 2015 Offsite<br />
Construction Awards<br />
The inaugural Offsite Awards has seen<br />
fierce competition with a flood of<br />
high-calibre entries competing to be<br />
crowned as industry leaders of the offsite<br />
construction market.<br />
With nearly 150 entries across 12<br />
categories, the awards have been packed<br />
full of outstanding, ground breaking<br />
projects, products and people. The winners<br />
will be announced at a relaxed drinks and<br />
nibbles reception, to be staged at the<br />
Inmarsat Conference Centre in London on<br />
December first.<br />
The awards ceremony will attract over 300<br />
national business leaders and high profile<br />
decision makers from the offsite<br />
construction industry, plus architects,<br />
engineers, contractors and clients,<br />
providing a significant platform for<br />
targeting the offsite industry. The event will<br />
also present the ideal opportunity for<br />
professionals to maximize industry<br />
exposure and penetrate this innovative<br />
market.<br />
Each of the judges has assessed four of the<br />
12 categories on a strict and confidential<br />
marking system to establish the award<br />
category winners, highly commended and<br />
shortlisted entries.<br />
Offsite construction sector raising the bar on<br />
skills<br />
Employers in the offsite construction sector have signaled the importance of<br />
working together to recognize and address skills gaps if they are to capitalize on<br />
the growth opportunities available to the sector.<br />
The employers, including Skanska and Laing O’Rourke, have led five skills projects cofunded<br />
by the UK Commission for Employment and Skills’ (UKCES) Futures Programme.<br />
The projects piloted different approaches to improve sector collaboration and provide<br />
better training opportunities for both new and existing workers.<br />
In October, UKCES published findings based on the delivery of these projects which<br />
demonstrate:<br />
• The clear need for industry leadership to capitalize on the opportunities afforded by the<br />
industrialization of the sector.<br />
• Employers can raise the bar on skills in sectors, regions and supply chains, by working<br />
with each other, their employees, universities and professional associations.<br />
• Collaboration has been shown to be vital to building the skills needed for growth and the<br />
topic of skills has brought competing businesses together to address their common<br />
need.<br />
• Competitors can become collaborators where there is a commonly experienced<br />
challenge which can be better tackled together, and where there is a foundation of<br />
strong individual or group relationships which can be built upon.<br />
• The breadth and depth of skill gaps were sometimes greater than project teams first<br />
realized, but in recognizing the gaps, corrective action could be taken. The report shows<br />
that it is crucial for employers in the sector to take responsibility and recognize these<br />
gaps otherwise they risk being left behind.<br />
• Educators and businesses must work more closely together to ensure educational<br />
institutions and professionals keep up with technological advancements and ensure<br />
innovation can be capitalized upon.<br />
Revolutionizing green building technology<br />
Smartphones, thermal imaging technology anad cloud computing could boost Europe’s<br />
ability to meet energy efficiency goals<br />
A €6.4 million project to revolutionize the way our industry delivers green buildings was<br />
launched in London on the 17th November. 20 UK and European partners will create new<br />
smart tools and cloud computing platforms to transform the energy efficiency and<br />
construction industries. Funded by our contributions to the Horizon 2020 programme – an<br />
€80 billion research and innovation fund – the ‘Built to Specifications’ (Built2Spec) project will<br />
use new technology to radically improve the design, installation and testing of building<br />
standards and retrofit. Together, the measures will help the built environment hit 2050<br />
carbon targets and reduce fuel poverty.<br />
CPA’s Skills Report ways to formalize<br />
construction training<br />
Manufacturers and distributors of construction products run thousands of training<br />
programmes for the builders and tradespeople who install their products. An<br />
opportunity exists to put that training on a formal footing with nationally recognized<br />
qualifications, a<strong>cc</strong>ording to a report from the Construction Products Association.<br />
‘Skills Report 2015’ – produced with support from the Construction Industry Training Board<br />
(CITB) – is the third in a series of projects that the CPA is contributing to understand skills and<br />
materials constraints facing the industry. It maps the large number of training activities which<br />
association members currently run, particularly for ‘product-users’, and recommends a new<br />
process to align that training to recognized qualifications.<br />
<strong>MMC</strong> Nov 2015 5
Product News ><br />
Setcrete puts in a<br />
High Performance<br />
Setcrete’s new High Performance floor<br />
levelling compound was found to be<br />
the perfect product for a problematic<br />
flooring installation at a home in<br />
Wythall, near Birmingham. By using<br />
Setcrete’s specialist, fibre-reinforced<br />
High Performance product, contractors<br />
were able to apply the levelling<br />
compound over both a plywood and a<br />
sand/cement screed subfloor in a<br />
single application - completing a<br />
perfect flooring installation, with a<br />
smooth, professional finish, in a matter<br />
of hours. And the rapid-setting<br />
properties of Setcrete High<br />
Performance meant that the newly<br />
levelled subfloor was ready to receive<br />
new floor-coverings in just four hours.<br />
UK first for Portaloo<br />
There are more than 230,000 people with disabilities in the UK who need more support and<br />
specialist facilities than standard a<strong>cc</strong>essible toilets provide. In response, Portaloo, part of the<br />
Portakabin Group, has launched Portaloo A<strong>cc</strong>essible Plus – the UK’s first self-contained, semipermanent<br />
toilet and shower building for wheelchair users and their carers which is available<br />
for short or longer-term hire.<br />
The building has a series of unique features including an integral, wheelchair-a<strong>cc</strong>essible<br />
shower for ease of washing, a weight-bearing ceiling track hoist for the safe transfer of users<br />
from a wheelchair to the WC, shower or changing bench, and a height-adjustable wash basin.<br />
Cembrit get a high five from the BBA<br />
Cembrit has the distinction of having its<br />
complete range fully a<strong>cc</strong>redited by the BBA<br />
(British Board of Agrément), holding five BBA<br />
Certificates for its fibre cement slate range.<br />
The Cembrit range of fibre cement slates<br />
includes Westerland, Moorland, Zeeland, Jutland<br />
and Diamond, all offering their own unique<br />
appearance. The slates are ideal for use on<br />
conventional pitched timber roofs with a rafter<br />
pitch of 20° and over, or hung vertically as<br />
cladding on external walls. The slates are<br />
complemented by matching fibre cement ridges,<br />
ventilation solutions, and fixings.<br />
All Portaloo A<strong>cc</strong>essible buildings are delivered fully<br />
plumbed in and fitted out, ready for immediate<br />
connection to water, waste and energy services.<br />
Portaloo will also provide foundations, Equality Actcompliant<br />
a<strong>cc</strong>ess ramps, and fast installation for the<br />
shortest possible procurement periods.<br />
www.portaloo.co.uk/a<strong>cc</strong>essible-plus.<br />
Manufactured to the highest European standards using Portland cement together with a<br />
formulation of superior blended synthetic and cellulose fibres, Cembrit fibre cement slates are<br />
finished with a high quality, semi-matt acrylic coloured coating to the face and edges and a<br />
tinted, high performance binder to the back face. Cembrit fibre cement slates are the most<br />
a<strong>cc</strong>redited on the UK market.<br />
www.cembrit.co.uk<br />
Zehnder launches new website<br />
The ‘flexible’ properties of Setcrete<br />
High Performance make it suitable for<br />
use over a wide range of subfloor<br />
types, including sand/cement screeds<br />
and, crucially, plywood. After overboarding<br />
the wooden subfloor with<br />
flooring grade plywood and applying<br />
Setcrete Acrylic Primer, contractors<br />
were able to apply High Performance<br />
onto the entire refurbishment area,<br />
including over both wooden and<br />
concrete subfloors, in a single<br />
application.<br />
www.setcrete.co.uk<br />
European indoor climate specialists Zehnder have relaunched<br />
their UK website, Zehnder.co.uk. Delivering an<br />
enhanced user-friendly experience with improved navigation<br />
and functionality throughout, it allows customers to a<strong>cc</strong>ess<br />
detailed product information and videos across multiple<br />
platforms. After registering for a my.Zehnder a<strong>cc</strong>ount users<br />
can also take advantage of a more personalised experience<br />
with the ability to save any brochures, planning<br />
documentation or data sheets to their own a<strong>cc</strong>ount, for<br />
immediate a<strong>cc</strong>ess in the future.<br />
“Our full range of BIM components are available for<br />
download, and application case studies provide a detailed<br />
overview of Zehnder’s capabilities across a wide range of sectors, including manufacturing,<br />
offices, schools and hospitals,” explained Zehnder Brand Manager, David Simoes.<br />
In addition to a richer online content, better presentation and the incorporation of video, the<br />
website’s powerful radiator filtering and product selector tools enable installers and specifiers<br />
to more easily find the most suitable products for their projects.<br />
www.zehnder.co.uk<br />
6
Product News ><br />
Cembrit to invest in<br />
natural slate<br />
Cembrit has announced the creation of<br />
a dedicated natural slates division to<br />
offer the UK’s specifiers and slaters<br />
greater choice of top end material for<br />
prestigious roofing contracts. The<br />
philosophy will be to enhance the<br />
existing range with additional high<br />
quality slates. The new brands will<br />
offer reliable, long term availability.<br />
This will be supported by dedicated<br />
personnel and focused marketing.<br />
Prater to continue involvement in London Bridge<br />
redevelopment<br />
Since November 2013, specialist contractor Prater has been on site at the redevelopment of<br />
the iconic London Bridge station carrying out the design, supply and installation of everything<br />
from the track-bed up. This includes the fabrication and installation of the pre-cast concrete<br />
platforms, as well as roof canopies with associated high level glazing. Lead contractor Costain<br />
has further appointed them to install a glazing package across the platform level, street level<br />
and retail areas of the site.<br />
Prater will design, engineer and install a bespoke structural glazing system, to meet the<br />
specification of the redevelopment, with the<br />
platform and street level system being installed<br />
along the St Thomas Street façade. In a later phase<br />
of the project, a 260m2 SU72 shopfront glazing<br />
screen will be added to the retail area.<br />
The 10-week programme on the St Thomas façade<br />
is due to commence in late 2015, with the six-week<br />
SU72 installation currently scheduled for Summer<br />
2017.<br />
www.prater.co.uk<br />
Loading up! Metsec takes student living to the next<br />
level<br />
Light gauge structural steel specialist voestalpine<br />
Metsec plc has supported the renovation of Portland<br />
House, Exeter, a 1960s concrete framed building -<br />
part of a £17m luxury student a<strong>cc</strong>ommodation<br />
scheme for developer Select Property Group, under<br />
its Vita Student brand. Originally a four-storey<br />
structure, Portland House has been converted into<br />
seven-storey student a<strong>cc</strong>ommodation, totalling 161<br />
high-end flats with the use of Metsec’s load bearing<br />
steel frame structure (SFS) system.<br />
Metsec’s load bearing SFS system enabled three additional storeys to be added to the original<br />
concrete building without impacting the structure, due to its lightweight design. These<br />
structures are stick built on site, which ensures maximum flexibility of the structure, and there<br />
was no need for the use of cranes to build the SFS. With land expensive and scarce in city<br />
centres, building upwards on existing structures is key to solving the shortage issue, and SFS<br />
has proved to be the most cost- and resource-effective way to do this.<br />
www.metsec.com<br />
As a start of the investment and long<br />
term commitment to Natural Slate, the<br />
group has decided to dedicate a<br />
specific person to this product group,<br />
Sales Director, Rob Wallace. Rob has 18<br />
years of experience in growing<br />
Cembrit’s business from its Welsh<br />
depot in Llandow, achieved through<br />
unbeatable customer service.<br />
“This marks the beginning of a new<br />
phase in Cembrit’s commitment to<br />
natural slate,” said Marketing Manager<br />
Ged Ferris. “Cembrit will be making<br />
substantial investments in this<br />
environmentally attractive material.<br />
Look out for more news as the division<br />
takes shape.”<br />
www.cembrit.co.uk<br />
David Wilson homes<br />
uses Vortice leto fan for<br />
prestigious new<br />
development<br />
A prestigious new development called Grey<br />
Towers Village in Nunthorpe near<br />
Middlesbrough will feature Vortice’s Leto<br />
fans in its three, four and five bedroom<br />
houses. The Vort Leto is an energy efficient centralised mechanical extract unit suitable for<br />
kitchen plus three wet rooms and is SAP Appendix Q listed.<br />
Roy Brown, Vortice Area Business Manager said: “Quite apart from its energy efficiency, the<br />
customer was particularly pleased with the quiet running of the Leto and the fact that it only<br />
required one breakout from the building.”<br />
Grey Towers village by David Wilson Homes combines the best of village life with the<br />
conveniences of modern living. It is built with a traditional village feel about it, including<br />
features like a beautiful pond, woodland and nature trails; the houses are spacious and<br />
incorporate energy efficient build methods.<br />
www.vortice.ltd.uk<br />
8
Offsite given wings<br />
Juliet Woodcock looks at a new concept surrounding modern methods of construction<br />
It has long been a<strong>cc</strong>epted that<br />
manufacturing construction elements in<br />
the factory environment is safer, ensures<br />
higher quality end products with reduced<br />
wastage and can help meet tight deadlines, as<br />
well as getting around the problem of the<br />
skills shortage we are still experiencing postrecession.<br />
But, as with every good idea, there is always<br />
someone who will take it one step further: on a<br />
large building contract, why not take the<br />
factory to the site? Indeed, a project funded<br />
through the Technology Strategy Board’s Low<br />
Impact Buildings Innovation Platform has<br />
undertaken a fundamental rethink of building<br />
processes, developing ‘flying factories.’<br />
Led by Skanska, the project involves partners<br />
from ModCell, Exelin *the South West<br />
Manufacturing Advisory Service), the University<br />
of Reading, and the Building Research<br />
Establishment. Together they have developed<br />
the system of ‘near-site’ manufacture using<br />
modern flying factories.<br />
To develop the technique and secure funding,<br />
Skanska’s innovation team put together a<br />
research consortium of external organizations.<br />
Inspiration was taken from the offsite<br />
fabrication of May Park School in Bristol.<br />
Combined with virtual-reality-enabled supply<br />
chain management and process improvement,<br />
the system can provide a 28 per cent reduction<br />
in cost per square metre and 30 per cent<br />
shorter programmes, delivering higher quality<br />
and a more predictable build.<br />
“With flying factories you are<br />
not tied into big overheads or<br />
high transport costs; and you<br />
are adapting the factory to<br />
exactly fit your needs at the<br />
time, so the concept is opening<br />
up the potential for a massive<br />
increase in the level of offsite<br />
fabrication across the country”<br />
Sam Stacey,<br />
Head of Innovation at Skanska<br />
The concept was used to assemble wall panels<br />
for Glenfrome School in Bristol, enabling a<br />
building extension to be completed in just six<br />
weeks during the summer holiday.<br />
It was then su<strong>cc</strong>essfully applied to the SRW<br />
engineering services project for the Battersea<br />
Power Station Development Company phase<br />
one, where 550 ‘utility cupboards’ have been<br />
created for residential use. Significant cost and<br />
programme savings have been recorded for<br />
both projects; for the Battersea scheme, cost<br />
and time savings of 44 and 65 per cent were<br />
achieved.<br />
If the Government is to reach its 2025<br />
construction targets of 33 per cent reduction in<br />
building costs and 50 per cent faster delivery,<br />
plus 50 per cent lower emissions, then near site<br />
factories could offer a significant part of the<br />
solution.<br />
Manufacturing components offsite, but close to<br />
the location for erection or installation helps to<br />
deliver many efficiencies:<br />
• Faster onsite installation<br />
• Minimal quality defects and associated waste<br />
• Optimized transport solutions to reduce costs<br />
• Overall reduction in operational and embodied<br />
carbon<br />
• Safer working environments for personnel<br />
• More likely to meet programme deliverables<br />
and reduce commercial risk<br />
• Avoiding the problems of poor weather<br />
10
Speaking exclusively to <strong>MMC</strong> Magazine, Sam<br />
Stacey, Head of Innovation for Skanska<br />
commented: “The concept of flying factories is<br />
that they are temporary and flexible so ideally<br />
they need to be located within 25 miles of the<br />
site where buildings will be located: so we will<br />
be looking at rented warehouse space or<br />
possibly temporary hire structures erected on<br />
hard-standing. Good transport connections with<br />
the final site are essential.<br />
Skanska has fabricated these large utility cupboards for an apartment project in Battersea,<br />
pre-fitted with all the M&E equipment including MVHR<br />
“It will also mean taking on labour on a<br />
temporary basis which, although it has not<br />
proved a problem to date, does require us to<br />
get people up to speed quickly in order to<br />
maximize the benefits. The approach then is to<br />
simplify the processes as far as possible,<br />
possibly taking steps out of the assembly<br />
process; and as much as possible making it like<br />
assembling a piece of furniture.<br />
“At present the design supply chain is not well<br />
established to facilitate this type of working,<br />
but we will look to use templates where we can.<br />
The advent of Building Information Modelling<br />
(BIM) also offers a good basis for progress and I<br />
believe we can benefit with 3-D modelling, as<br />
well as what we term ‘virtual rehearsals’. There<br />
is a degree to which we will have to be<br />
responsive to each type of assembly we have to<br />
work with. ”<br />
Apparently Sam Stacey’s team includes<br />
software specialists adept at working with<br />
virtual reality and they have already been<br />
experimenting with the Oculus type gaming<br />
headsets: making it possible to walk through<br />
some of the building prototypes currently being<br />
planned. This type of advancement could soon<br />
put the technology underpinning flying<br />
factories on an even footing with the<br />
automotive and other high tech industries.<br />
“I think this type of technology will be<br />
enormously helpful for those involved,”<br />
continued Sam Stacey, “To experience what we<br />
are proposing to build, including the<br />
construction sequence, and identifying any<br />
gaps in the design, or something we can<br />
improve in the process. It will be applicable to<br />
anything that can be produced as a pod:<br />
kitchens, bathrooms or the utility cupboards we<br />
have been producing for a residential<br />
development in Battersea – packed with the<br />
M&E equipment.<br />
“With flying factories you are not tied into big<br />
overheads or high transport costs; and you are<br />
adapting the factory to exactly fit your needs at<br />
the time, so the concept is opening up the<br />
potential for a massive increase in the level of<br />
offsite fabrication across the country.<br />
“ It is also a good environment to ‘tag and<br />
track’ all the components with RFID (Radio<br />
Frequency IDentity) tags which then facilitate<br />
quality checks and carry out condition<br />
monitoring to support condition based<br />
maintenance of moving and rotating<br />
machinery; particularly pumps.”<br />
Gary Peters from Exelin, reviewing the<br />
field tools for the tag and track solution<br />
Back in July, Skanska was additionally awarded<br />
£700,000 to develop construction robots, to be<br />
used to carry out several tasks, including<br />
cutting, drilling and fixing on site. The funding<br />
was awarded by Innovate UK and the<br />
Engineering and Physical Sciences Research<br />
Council (EPSRC) as part of their collaborative<br />
R&D programme; and it is expected that these<br />
robots will also be used in flying factories to<br />
further speed up the build process.<br />
Iain Gray, Chief Executive of the Technology<br />
Strategy Board, said of the flying factory<br />
notion: “The work we are funding will<br />
encourage the UK construction industry to<br />
undertake a fundamental rethink of current<br />
ways of working and enable businesses to<br />
explore potential commercial opportunities<br />
created by novel design, procurement and<br />
construction processes.”<br />
While capital investments are greatly reduced<br />
by rented space for flying factories, the pilots<br />
did reveal that the break in continuity of<br />
production could be an issue; which automation<br />
might overcome. Other lessons learned were<br />
that there needs to be an increased control<br />
over the start-up phase regarding decision<br />
making, early decisions and involvement of<br />
expertise, as well as increased control over the<br />
design and production process.<br />
<strong>MMC</strong> November 2015 11
New unitised curtain walling<br />
launched by Kawneer<br />
Glazing systems specialist Kawneer expands its curtain wall portfolio.<br />
Today’s safety-conscious and fast-paced<br />
construction schedules demand high<br />
performance, fast installation, simplified<br />
fabrication, superior performance and design<br />
flexibility.<br />
The DTI document “Manufacturing for the<br />
future” has long pressured the industry to<br />
increase awareness of off-site construction and<br />
build on the knowledge available across Europe<br />
and America.<br />
It clearly highlights that off-site construction<br />
should be considered for hotels, hospitals,<br />
schools and supermarkets. But in reality,<br />
because systems such as unitised curtain walling<br />
do not require scaffolding, they are suitable for<br />
any site where a<strong>cc</strong>ess is difficult or restricted - in<br />
itself a growing phenomenon, with 70% of newbuild<br />
now on brownfield sites.<br />
With curtain walling being one of the most eyecatching<br />
elements of a façade, its evolution from<br />
the traditional stick system to a unitised one is<br />
perhaps one of the most obvious signs that the<br />
Government’s drive off-site is being embraced.<br />
The factory production of unitised curtain<br />
walling from leading UK architectural aluminium<br />
systems supplier Kawneer gives predictability of<br />
time and cost, guarantees quality that reduces<br />
problems, delays and snagging on site, and<br />
avoids delays caused by adverse weather<br />
conditions.<br />
On-site time can also be reduced substantially,<br />
saving labour costs and minimising local effects<br />
such as noise, dust and traffic congestion. Where<br />
there is a shortage of skilled site labour, off-site<br />
manufacture ensures high build quality is<br />
maintained.<br />
Now Kawneer, which has 50 years of unitised<br />
curtain walling expertise, has enhanced its<br />
extensive curtain wall portfolio with the launch<br />
of a new fast-track dry-glazed unitised system.<br />
The AA ® 265 incorporates a three-chamber<br />
system and overlapping gasket design for<br />
optimum weather tightness. Its dry-glazed<br />
assembly combined with the use of the same<br />
extrusion to all four sides provides both ease of<br />
fabrication and the opportunity for effective bar<br />
optimisation.<br />
In addition, if a<strong>cc</strong>ess during installation is<br />
limited, the AA ® 265 system can be installed<br />
under restrictive working conditions, with the<br />
building remaining o<strong>cc</strong>upied.<br />
The optimum weathering is achieved by zonedrained<br />
pressure equalisation, with the glazing<br />
providing a positive weather seal for high<br />
performance. The system also features an<br />
exclusive high-performance thermal break.<br />
Its slim 65mm sightlines, picture-frame style<br />
capping, integral vent option and dual-finish<br />
gives specifiers a wide choice of options to<br />
create individual and exciting building facades as<br />
the AA ® 265 can a<strong>cc</strong>ommodate spandrel infill<br />
panels of glass, stone and metal up to 50mm.<br />
Adaptable to any new construction project from<br />
two storeys upwards, the AA ® 265 system has<br />
been exclusively designed and developed by<br />
Kawneer, with installation contracts undertaken<br />
in collaboration with its network of authorised<br />
dealers.<br />
Kawneer’s unitised range of curtain walling also<br />
includes the AA ® 201 unitised system which<br />
suites with the company’s AA ® 130 Brise Soleil,<br />
has 63.5mm sightlines and can a<strong>cc</strong>ommodate<br />
infill panels up to 32mm.<br />
As well as many of the features of its sister<br />
AA ® 265 system, the AA ® 201 is available with<br />
fully-capped and SSG (Structurally Silicone<br />
Glazed) options in addition to a horizontal cap<br />
with vertical silicone joint, vertical cap with<br />
horizontal silicone joint and a range of mullion,<br />
transoms and face cap options with 63.5mm<br />
Photo: David Cation<br />
St Andrew House,<br />
Glasgow<br />
AA ® 265<br />
Unitised<br />
Curtain Wall<br />
sightlines. Both the AA ® 265 and AA ® 201<br />
systems have been tested and certified to the<br />
stringent CWCT (Centre for Window and<br />
Cladding Technology) Curtain Wall testing<br />
standards.<br />
A more detailed guide to the benefits of unitised<br />
curtain walling for off-site construction are<br />
contained within Kawneer’s RIBA-approved CPD<br />
which advises architects and specifiers about<br />
the manufacturing process and testing regimes<br />
for such systems, how they are different to<br />
traditional “stick” curtain walling and how they<br />
are installed.<br />
Kawneer is also able to offer a range of stick<br />
curtain walling systems including the AA ® 100<br />
and AA ® 110 systems with 50mm and 65mm<br />
sightlines respectively. The AA ® 100 system is<br />
also available in a fire-rated version.<br />
Tel: 01928 502604<br />
www.kawneer.co.uk<br />
Click on the QR Code to view<br />
our 3D Interactive Model<br />
12
Revolutionis<br />
e<br />
your<br />
project<br />
delivery<br />
Skanska Fabrications can improve quality, minimise<br />
cost and reduce installation time on your project by<br />
manufacturing mechanical, electrical and plumbing<br />
system elements off-site.<br />
Our projects include commercial buildings such as<br />
30 St Mary Axe (the Gherkin), high quality residential<br />
apartments, schools and healthcare facilities,<br />
plus many more.<br />
To find out how you could save time and money,<br />
while improving on-site safety, contact us on<br />
01753 554215 or srw.enquiries@skanska.co.uk.<br />
www.skanska.co.uk
Article ><br />
Timber frame construction & the<br />
risk of disproportionate collapse<br />
A £1.4 million five-storey development of some 1,700 square metres, a<strong>cc</strong>ommodating 23 individual apartments,<br />
Aubrey Street in Herefordshire was a substantial project for timber frame specialists Taylor Lane.<br />
Versaliner liner Sheets<br />
Taylor Lane had been engaged by the<br />
main contractor Speller Metcalfe, an<br />
award-winning sustainable construction<br />
company, with expertise in BREEAM,<br />
Passivehaus and the Code for Sustainable<br />
Homes.<br />
The Project<br />
The development, for client Matches Housing<br />
Association, was to be constructed in close<br />
proximity to several existing properties on<br />
three sides. As is often the case with<br />
developments where space and a<strong>cc</strong>ess are<br />
restricted, off-site construction methods<br />
present an attractive solution. Taylor Lane<br />
specialise in manufacturing structural grade<br />
C16 timber frame panels in a quality-controlled<br />
factory environment.<br />
Prior to Aubrey Street, Taylor Lane’s timber<br />
frame panels incorporated an external<br />
sheathing layer comprising, typically, either<br />
OSB or plywood, depending on the application.<br />
Indeed, the specification for Aubrey Street had<br />
specified just these kinds of materials. Taylor<br />
Lane decided that something more was needed.<br />
The Challenge<br />
The close proximity of the site to other<br />
buildings and the risk of disproportionate<br />
collapse meant that the consequences of<br />
14<br />
a<strong>cc</strong>idental fire or even a possible arson attack<br />
had to be taken very seriously. This is a<br />
particular hazard faced by timber frame<br />
construction projects. In fact, the Structural<br />
Timber Association has launched several<br />
initiatives to combat this phenomenon,<br />
including detailed guidance.<br />
A<strong>cc</strong>ording to the STA guidance, “All buildings<br />
should have appropriate fire protection<br />
designed and built-in as early as possible and<br />
maintained throughout the entire construction<br />
phase… For small or low-risk sites, the general<br />
good housekeeping and standard approach<br />
may be more appropriate… For other sites the<br />
sub-division of the frame by fire-resisting<br />
barriers must be considered as part of the<br />
strategy for minimising fire spread risk during<br />
construction.<br />
The solution<br />
Aubrey Street certainly didn’t fall into the<br />
“small or low-risk” category. Consequently,<br />
Taylor Lane opted to use Euroform’s Versaliner<br />
instead of the specified OSB.<br />
Versaliner is an A1 non-combustible Magnesium<br />
Oxide sheathing board with excellent tensile,<br />
compression and breaking strengths, and high<br />
resistance to impact, moisture and insect<br />
attack. Excellent racking resistance means it is<br />
particularly suited to timber frame applications,<br />
offering additional stability. The fact that<br />
Versaliner is a “score and snap” materials<br />
means it can be fabricated on-site without the<br />
need for additional cutting equipment or can be<br />
seamlessly incorporated into the streamlined<br />
processes of off-site, factory-based<br />
construction.<br />
Taylor Lane worked closely with Euroform’s<br />
technical team, taking advantage of their<br />
expertise and experience in the complex area<br />
of passive fire protection, to ensure Versaliner<br />
was the appropriate product for this particular<br />
application.<br />
Duly satisfied that all their criteria had been<br />
met and all their concerns addressed, Taylor<br />
Lane began incorporating Versaliner into their<br />
timber frame panels as part of their off-site<br />
construction process.<br />
A spokesperson for Taylor Lane said,<br />
“Versaliner enabled us to safely build on a site<br />
where fire risk was a significant factor. Without<br />
it, we’d have struggled to proceed. We’re more<br />
than happy with the product, it’s very<br />
competitive pricing and ready availability.”<br />
www.euroform.co.uk
Can rooftop extensions be a solution to the housing crisis?<br />
The shortage of suitable land for housing, particularly in London,<br />
is recognised as one of the reasons why we are continually<br />
hearing about this nation’s housing crisis. During the 19th<br />
Century land was also at a premium and the advancement of<br />
engineering developments, including the first passenger lifts, made it<br />
possible to build habitable high rise a<strong>cc</strong>ommodation. This method of<br />
building continued to grow in popularity with many UK cities seeing a<br />
large number of high rise blocks erupting from the 1930s-1970s. Many<br />
of these buildings were over-engineered to such an extent that it is still<br />
possible for the structure and foundations to support up to 50% more<br />
floors than originally constructed. With the advances in engineering<br />
technologies in <strong>MMC</strong> this spare structural capacity can be exploited to<br />
provide a solution to housing needs without the need to use more land.<br />
Social issues and transport links aside, the first step in determining if a<br />
particular scheme is suitable is to identify which buildings are likely to<br />
gain planning approval and have the necessary structural engineering.<br />
If the structural report confirms there is sufficient integrity within the<br />
structure the next step is to identify which system is most appropriate<br />
for the intended purpose. Modular light gauge steel offers significant<br />
benefits and will fit many common situations.<br />
The solution on offer from Premier Modular Limited provides a cost<br />
effective, high quality system which will be constructed in an ISO9001<br />
and ISO14001 factory environment. The volumetric rooftop extension is<br />
then transported to site and installed with significantly reduced time on<br />
site and minimal disruption for existing residents. The Premier Modular<br />
system allows the roof to be factory fitted with the option of a vaulted<br />
ceiling. The end result is a high quality living a<strong>cc</strong>ommodation built to<br />
all relevant standards including Life Time Homes which can be<br />
mortgaged, complete with a 10 year insurance backed warranty through<br />
Checkmate.<br />
To find out how we can help you with your rooftop extension project,<br />
please contact us on 0800 316 0888 or<br />
graeme.odoherty@premiermodular.co.uk or 07824 303843<br />
<strong>MMC</strong> November 2015 15
Modular Volumetric ><br />
Portakabin Group wins<br />
Environmental Business of the<br />
Year award<br />
The Portakabin Group’s commitment to sustainability has been<br />
recognised with another award, having been named Environmental<br />
Business of the Year in the Yorkshire Post Environment Awards<br />
2015. The award was presented<br />
at an event in Leeds which<br />
celebrated the achievements<br />
of organisations working to<br />
combat global warming and<br />
create truly sustainable<br />
communities. This follows the<br />
Group’s su<strong>cc</strong>ess in a number of<br />
national awards for recycling<br />
and zero waste.<br />
Portakabin Group was<br />
honoured for its environmental<br />
commitments which cover<br />
every aspect of its business –<br />
from its achievement of<br />
generating zero waste to<br />
landfill in the manufacture of its market-leading modular buildings,<br />
to its sustainable transport initiatives which encourage cycling, car<br />
sharing and the use of public transport to reduce carbon emissions.<br />
www.portakabin-group.co.uk<br />
Portakabin Group awarded UK’s<br />
largest ever education sector offsite<br />
contract<br />
The London Borough of<br />
Barking and Dagenham<br />
has been awarded what<br />
is believed to be the<br />
largest ever off-site<br />
contract in the<br />
education sector, to the<br />
Portakabin Group – a<br />
£44m project to deliver<br />
an innovative threeschool<br />
campus.<br />
The 23,000m2 Riverside Schools scheme is one of the largest<br />
school projects now under construction and will provide additional<br />
places for one of the fastest-growing school-age populations in the<br />
UK. The campus will have capacity for around 2,700 children from<br />
0-19, integrating provision for nursery, primary, special needs,<br />
secondary, and sixth form.<br />
The Portakabin Group is main contractor for this pioneering<br />
project, and will use a Yorkon off-site solution for the curriculum<br />
areas. The use of off-site construction will significantly reduce the<br />
programme time; the project has been scheduled to complete the<br />
primary and SEN facilities in time for the start of the 2016/17<br />
academic year.<br />
www.yorkon.info<br />
Build with Confidence<br />
Magnesium Oxide Board Corporation enters the UK construction industry with the opening of new offices and warehousing facilities in<br />
Harlow Essex.<br />
MgO Corp has established a strong global foundation over the past 7years based on attention to detail and performance of our products,<br />
strong industry hands on knowledge and the highest professionalism aptitude in the building industry regarding mgo based composite<br />
products.<br />
Peace of Mind with The World’s Highest Level of Compliance<br />
ResCom ® building products and our manufacturing facilities are thoroughly audited by independent third party inspectors to assure the<br />
highest compliance for use in building and construction under multiple global building codes including but not limited to:<br />
United Kingdom: BS EN Standards 2015 - Australia: BCA Standards 2015 - New Zealand: NZBC Standards 2015 - Sweden: SWEDAC Standards<br />
2015 - Malaysian Standards Authority 2014 - Guatemala: FHA Standards 2015 - USA: ASTM - NAMI 2015.<br />
Lifetime Benefits<br />
MgO Corps ResCom ® building products greatly benefit us in all aspects of life by immediately<br />
decreasing global greenhouse gasses, lowering carbon footprint of developments and offering<br />
our families safer, stronger, healthier and more sustainable protection from the elements of<br />
water, wind, fire and the cold.<br />
ResCom ® Building Products are a direct replacement for traditional gypsum / plasterboard and<br />
FC linings. ResCom ® delivers revolutionary composite materials that are above FRL60 and<br />
reduce the use of fire rated wall lining from 67% to 50% without any reduction in<br />
performance (tested and proven). For further detailed information or to arrange a meeting<br />
contact: 01279442831 or email info@mgoboard.co.uk<br />
Mgo will stock their full range of board products from 4mm boards up to 25mm in lengths and<br />
widths of 1200 to 3000 and also their 18mm-22mm flooring products.<br />
Mgo will supply their quality Residential and Commercial ResCom ® boards to Builder’s<br />
Merchants Modular House Manufacturers, Construction Companies and other end users in the<br />
UK.<br />
wwwmgoboard.co.uk<br />
16
Ecological Insulation made from renewable resources<br />
Healthy Buildings and Lower Energy Costs<br />
Natural Insulation<br />
Natural Insulation Boards<br />
Flexible wood fibre suitable for<br />
roof, floor and timber frame wall<br />
applications. Excellent all round<br />
insulation properties improves the<br />
fabric and makes buildings a better<br />
place to live and work in whatever<br />
the weather.<br />
Wood fibre building boards for<br />
sarking, sheathing, acoustic and<br />
render applications. Diffusion<br />
qualities provide healthy living<br />
with protection against wind, dust,<br />
moisture and sound.<br />
For full details and nearest distributor<br />
call 01727 515120 or visit www.steico.co.uk<br />
10-34-76<br />
ENGINEERED<br />
BY NATURE
Article ><br />
STEICO – natural products for<br />
healthy buildings<br />
STEICO products are innovative building materials that offer long-term performance, increase the comfort of living<br />
and help to visibly increase the energy efficiency in buildings. STEICO products are especially economical and<br />
environmentally-friendly as they are produced from sustainable resources.<br />
STEICO Joist in roof application<br />
STEICO Special and STEICO<br />
Flex in a roof refurbishment<br />
< STEICO Joist close up<br />
Whether for engineered timber<br />
elements or insulation materials,<br />
roofing boards or wall panels,<br />
STEICO offers a suitable product for each<br />
building application. In the UK market STEICO<br />
is best known for its market leading I Joist<br />
which many of the major builders use in their<br />
developments. Increasingly smaller builders<br />
and developers are also changing from solid<br />
timber to I joists due to the performance, light<br />
weight and ease of a<strong>cc</strong>ess for service runs.<br />
Complementing STEICO joists a brand new<br />
state of the art 80,000 cbm Laminated Veneer<br />
Lumber plant has recently been commissioned<br />
and started production in September 2015. This<br />
makes STEICO unique in that it is the only<br />
European company to manufacture all the<br />
components of the I Joist. This gives<br />
distributors and end users a guaranteed robust<br />
supply channel with maximum control of costs<br />
going forward.<br />
STEICO is also the UK market leader in thin<br />
wood fibre underlay boards for use under<br />
laminate and wood flooring systems and is the<br />
product of choice for many professional floor<br />
fixers. Many of the own branded wood fibre<br />
underlay products in the major DIY chains are<br />
manufactured by STEICO. Other products<br />
showing significant growth in the UK are<br />
18<br />
boards for sarking applications, a partnership<br />
with Lime Green Products using Protect<br />
breathable render carrying board, and Flexible<br />
wood fibre batts in timber frame new build,<br />
refurbishment and commercial projects.<br />
All the insulation products benefit from the<br />
inherent properties of the natural materials<br />
that they are made from. The natural fibre<br />
insulation materials, for example, are<br />
distinctive as they offer diffusion qualities that<br />
contribute to a healthy indoor climate. The<br />
joists, used as construction elements, also<br />
follow nature’s examples and combine lean<br />
design and lightweight properties with a high<br />
load capacity. All products are easy to handle,<br />
non-allergenic and durable, real future proof<br />
building materials.<br />
Warm in winter – Cool in summer<br />
Worldwide more energy is used for cooling<br />
buildings than for heating them. Based on this<br />
it is reasonable to appraise the efficiency of an<br />
insulation product not only for its ability to<br />
prevent energy loss in winter months but also<br />
for its protection from heat ingress during the<br />
summer months. STEICO products provide a<br />
low thermal conductivity combined with a high<br />
heat storage capacity. Due to these special<br />
factors a comfortable cool environment in<br />
summer and a comfortable warm environment<br />
in winter can be achieved.<br />
Pro Environment – Pro Living<br />
While choosing materials and production<br />
methods, STEICO, as a producer of wood based<br />
ecological building materials, pays particular<br />
attention to the environment and healthy living.<br />
There is a clear commitment to meeting the<br />
needs of the present without compromising the<br />
needs of future generations with products that<br />
perform in both function and quality. The entire<br />
range of STEICO Insulation products are<br />
certified by FSC®, ensuring sustainable<br />
traceability of the raw wood fibre materials. In<br />
addition, the insulation boards also carry the<br />
seal of approval from the Passivhaus Institute<br />
and the Institute for Building Biology (IBR),<br />
Rosenheim, both of whom acknowledge the<br />
high energy efficiency performance gained by<br />
using STEICO products in many building<br />
applications.<br />
STEICO has its own sales and marketing office<br />
in the UK and its experienced staff offers<br />
technical advice on product use to supply chain<br />
partners, house builders, developers and<br />
Architects. Information can also be found on<br />
the company website.<br />
www.steico.co.uk
Across the board coverage<br />
Technical Editor, Bruce Meechan hears from Ged Ferris of Cembrit about the wide selection of board products the<br />
manufacturer can offer for internal and external construction applications.<br />
The term one-stop-shop may be over<br />
used in the UK building products supply<br />
chain, but the range of boards offered<br />
by long-established manufacturer, Cembrit<br />
can provide specifiers with solutions to every<br />
sort of challenge from interior refurbishment<br />
and the creation of wet rooms within social<br />
housing units, to some of the most daunting<br />
logistical demands faced by burgeoning offsite<br />
or <strong>MMC</strong> sector.<br />
.The majority of the board options offer not just<br />
excellent physical characteristics, but a strong<br />
lineage and a long track record of service, both<br />
here and on the Continent.<br />
The SP board offers a very rapid means of<br />
effectively tanking a room<br />
As UK Marketing Manager, Ged Ferris,<br />
commented during our interview: “We have the<br />
product range to facilitate the needs of<br />
everyone from offsite system fabricators to<br />
refurbishment specialists and the growing selfbuild<br />
market.<br />
Not just a Five-star range, but a range with five<br />
main stars and many product variations:<br />
Cembrit’s flat boards encompass all the key<br />
performance parameters including moisture<br />
resistance, fire resistance and structural<br />
strength, as well as providing a versatile<br />
substrate for commonly used finishes.<br />
THE RANGE General purpose and specialist<br />
requirements solved by Cembrit’s boards<br />
The product within the range which has shown<br />
the most rapid growth across the market is PB:<br />
a versatile tile backer or render backer board,<br />
mainly being used for the refurbishment of<br />
bathrooms, it is popular due to its low weight<br />
and ease of cutting which facilitates<br />
installation, and the robust long term<br />
performance. Cembrit has developed a version<br />
called Flex which can be fixed down to radii of<br />
just 150 mm. Both conventional PB and Flex<br />
features polystyrene spherules and an edge<br />
reinforcement detail that uses a special fabric<br />
allowing butt jointing and fixings close to edges<br />
This Walsall project shows a<br />
typical sheathing application<br />
for Cempanel before final<br />
cladding is installed<br />
for maximum rigidity. Flex installations might<br />
then form a column casing that would be<br />
rendered over or covered with a small format<br />
mosaic.<br />
Where social housing providers are seeking to<br />
fit out full wet rooms for those who might need<br />
assistance with personal care, then there is also<br />
a Special Performance board which was<br />
originally developed for use in places like<br />
swimming pools.<br />
The biggest seller still, though in terms of<br />
volume is Cempanel which is primarily specified<br />
for dry-lining and sheathing: the internal skin to<br />
a rainscreen cladding build up. Depending on<br />
dimensions, Cempanel can also take racking<br />
Making the right board decision<br />
Cembrit FR Fire rated building board<br />
Cembrit Cempanel High strength panels for external<br />
sheathing in rainscreen cladding systems<br />
Cembrit HD Heavy duty external building<br />
board for agriculture and construction<br />
20
loads: being produced in thicknesses of 8, 10, 12<br />
and 16 mm. It is also often used as a render<br />
carrier in exterior applications.<br />
The Cembrit range of high performance board products is ideally suited to use<br />
by the offsite sector as well as for refurbishment and other applications<br />
The FR board can provide up to 120 minutes of<br />
fire resistance and is widely specified for soffits<br />
in corridors, lift lobbies and other communal<br />
“We see our board range as<br />
being of particular value to<br />
manufacturers of modules,<br />
pods, timber frame panel<br />
systems and other<br />
prefabricated solutions.<br />
They could even form the<br />
face to SIPs (Structural<br />
Insulated Panel) systems.”<br />
Ged Ferris, UK Marketing Manager, Cembrit<br />
Fire resistance approval testing on FR board<br />
areas to buildings where the consideration of<br />
escape routes and combating the surface<br />
spread of flame are essential.<br />
Ged Ferris added: “We see our board range as<br />
being of particular value to manufacturers of<br />
modules, pods, timber frame panel systems and<br />
other prefabricated solutions. They could even<br />
form the face to SIPs (Structural Insulated<br />
Panel) systems.<br />
“As well as the merchant stockist, clients can<br />
also purchase through ‘optimizers’ – board<br />
cutting specialists who supply the exact sizes<br />
they need to make our standard product<br />
PB Flex used as a tile backing<br />
coordinate with elevation widths, window<br />
openings and things like flues or other service<br />
penetrations. It will also be a real advantage to<br />
customers that such a comprehensive selection<br />
is available from a single source.”<br />
Responding to market demand, Cembrit is also<br />
making its cladding boards available as BIM<br />
objects in partnership with its Scandinavian<br />
parent company. These can be viewed via the<br />
company’s website at www.cembrit.co.uk or by<br />
contacting the company’s technical advisory<br />
service via email.<br />
www.cembrit.co.uk<br />
couldn’t be easier with Cembrit.<br />
Cembrit PB Baseboard for external<br />
render or wet area tiling<br />
Cembrit Multi-purpose Easily cut board with good<br />
impact resistance for panels, strips and partitions<br />
With a range of boards that<br />
satisfy the requirements of most<br />
lining, panelling and baseboard<br />
applications Cembrit building<br />
boards are ideal for off site<br />
construction. Cembrit can<br />
supply mixed loads to ease your<br />
stockholding.<br />
Unit 1a, Normanton Industrial Estate,<br />
Nr Leeds W. Yorkshire WF6 1TN.<br />
T: 01924 890890 F: 01924 897<strong>48</strong>7<br />
E: info@cembrit.co.uk www.cembrit.co.uk<br />
<strong>MMC</strong> November 2 2015 16:<strong>48</strong> 21
Spantherm - the insulated precast<br />
concrete ground floor system<br />
Thermal, structural, sustainable<br />
Spantherm is a pre-insulated precast<br />
concrete flooring system designed<br />
specifically for residential and mid sized<br />
commercial ground floors. The composite slab<br />
combines structural concrete and high<br />
performance Expanded Polystyrene (EPS)<br />
insulation to provide a superior thermal floor.<br />
Cavity Wall<br />
Insulation<br />
Spantherm Unit<br />
Why use Spantherm?<br />
• More efficient than beam and block<br />
• Faster installation on site<br />
• Excellent thermal performance with a U-value<br />
as low as 0.12 W/m2K<br />
• Provides a flat, safe working platform with all<br />
insulation below the structural slab<br />
• Eliminates cold bridging<br />
• Significantly reduces on site construction time,<br />
labour and waste<br />
• Structural floor ready to build off next day<br />
• No need for expensive storage for insulation<br />
• Install with existing plant and machinery<br />
DPC<br />
Localised<br />
Bearing Point<br />
Blockwork<br />
Support<br />
Grout<br />
Concrete<br />
Element<br />
Insulation<br />
Element<br />
The Complete Service Package<br />
Creagh Concrete, established in 1976, is one of the largest and most innovative producers of<br />
concrete products for a diverse range of market sectors throughout Ireland and the UK.<br />
The team offers a comprehensive design service which includes provision of CAD based<br />
drawings along with all relevant structural and thermal design calculations. On completion<br />
of the project, a design certificate will be provided along with calculations for your project.<br />
With bases throughout the UK, Creagh Concrete offers rapid nationwide delivery and<br />
exceptional customer service and flexibility. This ethos is combined with a diverse portfolio<br />
of products that showcases the limitless possibilities and potential of precast concrete.<br />
Visit www.creaghconcrete.co.uk/spantherm or email info@creaghconcrete.com<br />
for further information on Spantherm and the full product range<br />
22
The structural envelope<br />
has now been pushed<br />
ICF goes<br />
Offsite<br />
High Insulation Level<br />
High Strength<br />
High Build Speed<br />
But<br />
Low Cost<br />
Low Skill Levels<br />
With<br />
No Drama<br />
Polarwall www.polarwall.co.uk 0845 838 2181<br />
<strong>MMC</strong> November 2015 23
Acoustic Fire &<br />
Thermal ><br />
Simple airtightness<br />
solution is a BBA first<br />
Specifiers and architects looking for a<br />
straightforward but healthy and effective<br />
air tightness solution for buildings need<br />
look no further than Wraptite-SA.<br />
The abilities of this single-component,<br />
externally applied air barrier from the A.<br />
Proctor Group have now been officially<br />
recognised by the BBA following<br />
comprehensive assessment at its<br />
laboratory in Watford. The product makes<br />
a significant contribution to a building’s<br />
thermal performance by preventing<br />
lateral air movement, but also helps<br />
maintain a healthy living environment<br />
and structure thanks to its high vapour<br />
permeability rating (Sd 0.039).<br />
The self-adhering membrane fully bonds<br />
to virtually any substrate, requiring no<br />
mechanical attachment, seals or tapes to<br />
suppress air leakage around junctions or<br />
penetrations.<br />
Skanska specifies Cygnus for new city building<br />
The Monument Building in the heart of the City of London is one of the current projects to<br />
use Bull Products’ latest Cygnus wireless alarm system during construction works. Standing<br />
adjacent to The Monument, which marks the origin of the Great Fire of London, the 88,000sq<br />
ft office a<strong>cc</strong>ommodation is split over ten floors with terraces at several levels.<br />
Skanska has been using the Bull Products system since<br />
construction started last year, specifying some 26 units.<br />
Intended purely for use on construction sites, the CE marked<br />
Cygnus system has been specifically designed for use in dense<br />
concrete and steel structured buildings and areas where there<br />
are many other radio frequencies in operation.<br />
The Cygnus alarm system can link as many as <strong>48</strong>0 alarm and<br />
detector units in different zones on a construction site, and<br />
individual units can be fire alarm call points, first aid alerts,<br />
combined call points and first aid alerts, smoke detectors, or<br />
heat detectors.<br />
www.bullproducts.co.uk<br />
Knauf Facades simplifies school construction<br />
Timely technical support reinforced with on-site<br />
inspections led to CRT Construction to choose SFS<br />
systems from Knauf Facades when engaged by Wates<br />
Construction in the project to build the £4.7 million<br />
Garston Manor SEN school in Watford.<br />
The single storey 3,000m2 building provides 120<br />
places for students aged 11 to 16 years and features<br />
flexible teaching spaces, food technology, art, drama<br />
and science areas, specialist sensory rooms and<br />
pastoral care units.<br />
All Knauf Exterior Wall Systems have been fully designed and tested for their structural,<br />
thermal, fire and acoustic performance in collaboration with UKAS laboratories and industry<br />
leading consultants such as the Steel Construction Institute (SCI). Fire safety is operational<br />
from the start, allowing for high levels of fire protection during construction, as well as once<br />
the project is complete.<br />
www.knauf.co.uk<br />
Wraptite-SA has received BBA<br />
certification (no. 15/5274) for use in both<br />
roofs and in walls behind the rain screen<br />
cladding making it an ideal choice for<br />
commercial projects with large<br />
uninterrupted facades.<br />
Key construction benefits:<br />
• Air tightness - as well as wind<br />
resistance during construction<br />
• Water resistance - providing<br />
temporary protection for the<br />
building fabric during construction<br />
• Breathability - allows vapour to<br />
escape reducing condensation for<br />
users and structure<br />
• One-piece solution – requires no<br />
tapes<br />
• Self-adhering- reduces mechanical<br />
fixings of the membrane and<br />
ensures less risk of water/wind<br />
without limiting vapour<br />
permeability<br />
www.proctorgroup.com<br />
Eurocell helps transform market into Nottingham’s<br />
Creative Quarter<br />
Technical support from Eurocell has contributed to the<br />
£3.85 million redevelopment of Sneinton Market that<br />
planners believe will transform it into the Nottingham’s<br />
own Covent Garden.<br />
Wates was appointed as main contractor to refurbish<br />
three of the five 'avenues' at Sneinton Market, funded<br />
through a £2.44m European Regional Development<br />
Fund (ERDF) grant and a further £1.45m from the City<br />
Council. And Wates selected Derbyshire Floorcraft to<br />
refurbish the 8 x 80m long lean-to roofs that are an integral part of the market’s particular<br />
appearance.<br />
“Eurocell provided outstanding service,” says Darren Scarborough of Derbyshire Floorcraft. “It<br />
modified one of its conservatory roof products and produced it in a bespoke colour, anthracite,<br />
so it was in keeping with the heritage nature of the site and sent its architect and design team<br />
to site to make sure it all fitted properly. The result is a design that matches the original<br />
Victorian design but delivers a 21st century performance.”<br />
www.eurocell.co.uk<br />
24
Totally drained...<br />
Range of products changing approach to modern methods of residential drainage<br />
“The systems have been specifically designed<br />
to provide flexible solutions to problems that<br />
face those building residential property every<br />
day. They meet the best-practice requirements<br />
of all current SuDS guidance and legislation.”<br />
Providing a more natural approach to managing<br />
rainfall, Skeletank is a Surface water drainage<br />
system (SuDS) that can deliver provide both<br />
infiltration and attenuation. Skeletank solutions<br />
are suitable for pervious, impervious and softlandscaped<br />
surfaces making them incredibility<br />
flexible in use.<br />
Designed to manage surface water run-off<br />
within the grounds of each individual property,<br />
the system can return the water to the ground<br />
and/or store the water before releasing it in a<br />
controlled manner to the mains sewer network,<br />
or adjacent watercourses.<br />
Arange of products is now proving<br />
popular with construction companies<br />
looking for innovative and modern<br />
methods following its launch earlier this year.<br />
Skeletank is now set to take the UK house<br />
construction market by storm, offering a<br />
solution to addressing the issues faced by<br />
residential builders when designing and<br />
installing surface water drainage systems.<br />
...Skeletank systems offer<br />
ground breaking design<br />
benefits to residential<br />
drainage schemes,<br />
gathering rainwater at<br />
source and allowing its<br />
controlled release...<br />
Providing innovative sustainable drainage<br />
systems (SuDS) designed specifically for<br />
residential properties, Skeletank is only<br />
available from Hydro Water Management<br />
Solutions (Hydro WMS) and is the first modular<br />
systems of its type in the UK.<br />
Adhering to the management train laid out in<br />
CIRIA C697, Skeletank systems bring with them<br />
26<br />
a host of benefits for residential developers,<br />
social housing companies, local authorities and<br />
construction companies.<br />
Potential benefits include releasing more land<br />
for development; substantial reduction in<br />
upfront costs of adoptable networks; improved<br />
cash-flow for developers; CDM and Health &<br />
Safety benefits and most importantly, the<br />
reduction of flood risk.<br />
Director of Hydro WMS Brian Byrne explains<br />
further: “Skeletank systems offer ground<br />
breaking design benefits to residential drainage<br />
schemes, gathering rainwater at source and<br />
allowing its controlled release, either naturally<br />
back into the environment, or into the sewer<br />
network at a manageable rate.<br />
This modern method of managing surface<br />
water run-off at source can reduce the up-front<br />
cost of adoptable networks and provide major<br />
cash-flow benefits to developers. It may also be<br />
possible to reduce the size of<br />
open water features on site,<br />
such as ponds, thus allowing<br />
more room for more<br />
properties on the same sized<br />
site.<br />
The main components of<br />
Skeletank systems are<br />
designed to be installed at a<br />
shallow level beneath<br />
hardened surfaces with<br />
minimal cover. This also<br />
proves extremely costeffective,<br />
especially where<br />
there are ground issues such<br />
as contamination, high water<br />
tables or underlying rock layers. This reduced<br />
excavation means that the CDM benefits are<br />
huge, and staff safety is looked after, which is<br />
important in the world of construction.<br />
Brian concluded: “It is an exciting time for<br />
Skeletank as more and more home builders are<br />
having to look for innovative ways to deal with<br />
water and there are now stringent SuDS<br />
guidelines to be followed. We not only make life<br />
easy, but we offer so many other benefits, that<br />
Skeletank is poised to be a market leader used<br />
by large and small private and public<br />
developers.”<br />
More information about the<br />
Skeletank range is available at<br />
www.skeletank.co.uk
SPECIFY<br />
JJI-JOISTS<br />
AND WE’LL<br />
GIVE YOU<br />
AN I-FULL.<br />
You can rely on JJI-Joists to su<strong>cc</strong>eed–whatever the challenge, because JJI-Joists are jam packed with features to make your life<br />
easier, and the job quicker. We are the most popular I-Joist in the UK and the I-joist most specified by architects and engineers.<br />
So, whether designing or building, choose JJI-Joists with confidence. You’ll find there’s so much more to them than meets the eye.<br />
WEB: www.jamesjones.co.uk/ewp EMAIL: jji-joists@jamesjones.co.uk
Article ><br />
Offsite construction – healthcare’s<br />
complete turnkey solution<br />
The capabilities of offsite more than match traditional build. Patient wards, theatres, A&E departments and<br />
cleanrooms can all be designed, built and delivered in just 12 weeks using modular methods of construction,<br />
reducing the need for interim short-term hire.<br />
> The extension has created six, six-bed wards and 15 single bedrooms<br />
with several link corridors to improve circulation within the hospital.<br />
For the first time, many healthcare<br />
establishments are considering offsite<br />
construction because of its costeffective<br />
nature and the efficiencies it<br />
provides.<br />
Matthew Goff, UK Operations Director at<br />
Actavo | Building Solutions – formerly known as<br />
Roan Building Solutions – explains how<br />
Business Information Modelling (BIM) has been<br />
integrated into offsite methods of construction<br />
and the benefits it provides.<br />
BIM – providing insight into the future of<br />
healthcare<br />
With many NHS trusts already in debt and the<br />
whole service facing unprecedented financial<br />
challenges, the introduction of BIM offers some<br />
hope for estates managers looking to deliver<br />
savings while enhancing quality.<br />
Actavo | Building Solutions is one of the first<br />
offsite construction companies to meet BIM<br />
Level 2 and it has been fully integrated into the<br />
business since June 2015. Instrumental in<br />
winning new business, Actavo | Building<br />
Solutions can now showcase the true benefits<br />
of offsite build as a quick, cost-effective and<br />
high-quality solution.<br />
Modular buildings can now be built to any<br />
specification – BREEAM, Passivhaus or AECB.<br />
As BIM helps extend design life, it can exploit<br />
advances in materials and improvements in<br />
sustainability and energy efficiency.<br />
than traditional build – which impacts on bed<br />
availability.<br />
Modular build is making the construction<br />
industry safer due to shorter construction and<br />
build times – just four weeks in some cases – as<br />
well as the buildings being manufactured in<br />
more quality controlled environments. These<br />
factors combine to make it easier for estate<br />
and facilities managers to plan and re-direct<br />
resources.<br />
New build case study: paediatric wing<br />
Cork University Hospital, Ireland, has added a<br />
brand new, single-storey €3.4m paediatric wing<br />
to its centre of excellence with a design and<br />
build project delivered by Actavo | Building<br />
Solutions.<br />
The extension sits on top of the ground floor of<br />
Cork University Hospital and has created six,<br />
six-bed wards and 15 single bedrooms with a<br />
total 1600m2 of additional floor space and<br />
several link corridors to improve circulation<br />
within the hospital.<br />
The Cork University Hospital extension was<br />
difficult to reach as it is located above a<br />
working ward within a courtyard and with<br />
limited road a<strong>cc</strong>ess. Even so, the new<br />
paediatric wing was completed in June 2015<br />
and took just 26 weeks to complete using<br />
modular methods of construction, meaning<br />
that 80% of the programme took place offsite.<br />
Actavo | Building Solutions also mirrored the<br />
existing external brick slip front so the<br />
extension was aesthetically-attuned with the<br />
rest of the hospital, as well as also fitting a<br />
pneumatic drug circulation system to both the<br />
new and existing building.<br />
Environmental design features included<br />
measures to support air-tightness and sound<br />
insulation.<br />
www.actavo.com<br />
However, where offsite comes into its own is<br />
the cost-saving delivered through speed of<br />
delivery – sometimes up to 50 per cent quicker<br />
> Cork University Hospital’s new modular, first-storey, paediatric wing was completed<br />
in just 26 weeks and mirrors the external brick slip front of the original building.<br />
28
Combining the next generation of DuraSpin collated<br />
screw driving tool systems with innovative fastener<br />
design has resulted in the most efficient fastening<br />
solution for the expanding steel framing<br />
construction market. Senco has the complete<br />
system to maximise your productivity and quality<br />
while minimising down time and waste.<br />
Poppers Senco UK Ltd.<br />
Tel: 01925 445566<br />
Fax: 01925 418873<br />
sales@poppers-senco.co.uk<br />
www.poppers-senco.co.uk<br />
ICARUS L.S.F. PROJECT
Article ><br />
New ‘super school’ built offsite<br />
<strong>MMC</strong> Magazine looks at how the London Borough of Barking and Dagenham has embraced factory fabrication to help<br />
meet its rapidly rising need for education places.<br />
The 23,000 square metre Riverside Schools scheme is one of the largest<br />
education projects now under construction and will provide additional<br />
places for one of the fastest-growing school-age populations in the UK.<br />
Barking and Dagenham has one of the highest<br />
growth rates of school age children, driven in<br />
part by an ambitious housebuilding programme<br />
which is already under way. As a result there is<br />
the need for the primary school and SEN<br />
facilities to be delivered ahead of the rest of<br />
the campus, with these being set to open in<br />
time for the start of the next academic year in<br />
autumn 2016. The flexibility of the Yorkon<br />
offsite solution is making this not just possible,<br />
but practical - while the whole project is due for<br />
completion in spring 2017.<br />
The pressures on the UK’s education<br />
system are well documented and<br />
increasing, but the solutions far less<br />
evident. However, in East London the Yorkon<br />
Group company, Portakabin has been<br />
instrumental in helping deliver what is<br />
believed to be the largest ever offsite contract<br />
in the education sector..<br />
The Riverside Schools scheme in the London<br />
Borough of Barking and Dagenham covers<br />
23,000 square metres and stretches from<br />
nursery to age nineteen across three free<br />
schools, with the £44 million cost coming from<br />
the Education Funding Agency. Portakabin’s<br />
contract for all of the “curriculum spaces” was<br />
awarded via the council’s Thames Partnership<br />
for Learning.<br />
When complete the campus will a<strong>cc</strong>ommodate<br />
a 10-form entry secondary school, a 630-place<br />
primary school, a special educational needs<br />
(SEN) school, and a nursery. It will also offer<br />
extended provision outside school hours as well<br />
as wider use at weekends and during school<br />
holidays; to contribute to the local community.<br />
Roger Leighton is Chief Executive of<br />
Partnership Learning which will operate the<br />
three schools on the campus, and commented:<br />
“We have had a very good first-hand<br />
experience of the Portakabin Group’s offsite<br />
solutions as our schools currently o<strong>cc</strong>upy two<br />
earlier phases on a site near the planned<br />
Riverside Schools campus. We have been really<br />
impressed with the quality of the finished<br />
buildings, the speed of construction, and just<br />
how far offsite technology has now advanced.<br />
“The Portakabin Group makes good use of<br />
architectural design to the benefit of the users<br />
and to enhance the internal environment. As<br />
an example, our strong preference is for 75<br />
square metre classrooms which are<br />
significantly larger than the 56 square metre<br />
classrooms required by the Department for<br />
Education. With careful design and planning,<br />
use of a Yorkon offsite solution gives us the<br />
flexibility to achieve this and for almost the<br />
same budget – which is a very key benefit.”<br />
Speaking to <strong>MMC</strong> Magazine during the Offsite<br />
show at London’s Excel Centre, Simon Ambler.<br />
Director of the Portakabin Group said: “We<br />
have been building a very good relationship<br />
with the London Borough of Barking and<br />
Dagenham – this is our seventh project for the<br />
council. The contract demonstrates how the<br />
Yorkon building solutions can be employed to<br />
meet the urgent need for school places, and<br />
early engagement here has been important<br />
because of the borough’s desire to build to nonstandard<br />
sizes.”<br />
The group has invested in a new plant in York<br />
which feature’s Europe’s largest press for such<br />
systems, while also developing a new system<br />
that is not only flexible in terms of its space<br />
dimensions but also the way it can link to<br />
existing buildings<br />
Simon Ambler concluded: “We expect this<br />
project to change the face of off-site<br />
construction in the education sector.”<br />
www.yorkon.co.uk<br />
“The Portakabin Group makes good use of architectural design to the benefit of the users and to enhance the<br />
internal environment. As an example, our strong preference is for 75 square metre classrooms which are<br />
significantly larger than the 56sqm classrooms required by the Department for Education. With careful design and<br />
planning, use of a Yorkon offsite solution gives us the flexibility to achieve this and for almost the same budget.”<br />
Roger Leighton, Chief Executive of Partnership Learning.<br />
30
Engineered solution ><br />
...with a certified performance designed to overcome<br />
skills shortages & meet building regulations<br />
Article ><br />
As widely reported, the recession caused a vast fall in the demand for bricks, resulting in many kilns ceasing to<br />
manufacture and bricklayers having to find alternative employment. As the industry emerged from the downturn,<br />
in 2014, it became clear that housebuilders were challenged by two major factors - a shortage of materials and<br />
traditional labour skills.<br />
Although many businesses grappled to<br />
find the best way forward, Alumasc<br />
Facade Systems turned this situation<br />
into an opportunity by developing a new and<br />
innovative facade technology designed<br />
specifically for the offsite structural timber<br />
sector – the Alumasc Ventilated System<br />
(AVS).<br />
AVS meets all UK ventilation standards for<br />
timber framed buildings and offers an<br />
industry-leading A2 Fire Performance Rating,<br />
together with the highest levels of impact<br />
resistance and is suited to all exposure levels.<br />
AVS complies with the requirements of both<br />
the NHBC and TRADA, namely the need for<br />
ventilation for structural timber construction,<br />
with a minimum of 15mm ventilated cavity for<br />
NHBC and 25mm for TRADA.<br />
The system a<strong>cc</strong>ommodates a range of cavity<br />
depths - the free-flowing system ensures that<br />
the substrate remains continuously ventilated<br />
and prevents any moisture tracking back to<br />
the primary structure, removing condensation<br />
– providing a protective facade.<br />
Offering an alternative method of<br />
construction, AVS can replicate any brick in<br />
the market via patented, lightweight acrylic<br />
brick slips. The system is not just limited to<br />
using acrylic brick slips as the final facade<br />
Technical Approval<br />
The AVS system has been rigorously tested,<br />
resulting in compliance with all UK Building<br />
Regulations and became British Board of<br />
Agrément approved (Cert No: 15/5211) in May<br />
2015. It is the only ventilated system in the UK<br />
to be BBA certified with an external acrylic<br />
The initial product development remit was to<br />
design a ventilated system that would<br />
replicate traditional building aesthetics, whilst<br />
providing a lightweight solution that could be<br />
fixed directly to structural timber systems.<br />
Alumasc’s main goal was to ensure the system<br />
was engineered to deliver structural stability<br />
across all applications whilst providing<br />
adaptability to all forms of structural timber<br />
construction.<br />
This innovative, engineered system provides<br />
the solution to overcome the fundamental<br />
issues of the brick shortages. AVS, as an<br />
offsite manufactured system, improves<br />
efficiency and speed of construction,<br />
addresses skills shortages and enhances the<br />
quality of finish, whilst delivering the final<br />
aesthetics to meet the exacting requirements<br />
of architects, designers and housebuilders.<br />
The product offers specifiers a ventilated<br />
cladding solution for timber frame<br />
construction (open and closed panel<br />
technology), together with volumetric<br />
modular and structurally insulated panel<br />
systems (SIPS). It protects the fabric of the<br />
building whilst providing a wide choice of<br />
aesthetic options.<br />
finish - it is also approved for use with<br />
textures, through-coloured silicone renders,<br />
along with an extensive range of dashing<br />
renders.<br />
AVS is erected via Alumasc’s network of<br />
registered installers to ensure correct<br />
application onsite. The AVS installer training<br />
programme is independantly assessed and<br />
approved by the BBA. AVS comes with a 10<br />
year warranty offer for all projects installed<br />
by an Alumasc registered contractor.<br />
brick slip finish and offers an industry-leading<br />
A2 rating, providing the building with<br />
improved fire performance when compared to<br />
other cladding solutions.<br />
During the development of the system,<br />
Alumasc worked very closely with a number<br />
of companies and bodies to ensure AVS would<br />
meet the demands of the offsite and onsite<br />
construction industry, whilst providing<br />
optimum performance and longevity. These<br />
organisations include CCG, Exova Fire<br />
Research, Warrington (fire testing); Lucideon<br />
(UKAS a<strong>cc</strong>redited testing body); Pell<br />
Frishmann (Consultant Engineers) and the<br />
British Board of Agrément.<br />
AVS is the solution to overcome current<br />
construction industry skills issues and is wellpositioned<br />
to be part of the building<br />
technology of the future.<br />
To book a CPD seminar please email:<br />
facades@alumasc-exteriors.co.uk<br />
www.alumascfacades.co.uk/avs<br />
<strong>MMC</strong> November 2015 31
Article ><br />
Building fabric in the firing line<br />
Technical Editor Bruce Meechan reports from the Inmarsat Centre in London about a wide ranging conference<br />
staged there on November 18th.<br />
and perhaps this points to why so many of our<br />
modern or recently overclad properties suffer<br />
from condensation problems.<br />
Several of the speakers touched on the subject<br />
of dwellings overheating, with the various<br />
remedies recommended including greater use<br />
of thermal mass and concrete or masonry<br />
elements, better attention to the detailing and<br />
construction of ductwork serving MVHR or<br />
other ventilation systems, and also solar<br />
shading or shutters.<br />
There have been many times when I have<br />
sat through a chairman’s opening<br />
remarks at a construction conference<br />
and wondered if I wouldn’t have been better<br />
hanging around in the foyer for a second cup<br />
of tea – but not so with what Rob Pannell from<br />
the Zero Carbon Hub had to say at the Fabric<br />
First event, staged in London’s very<br />
a<strong>cc</strong>essible Inmarsat Building by Radar<br />
Communications.<br />
While I don’t share the Zero Carbon Hub’s<br />
certainty about Global warming, amongst his<br />
many observations that struck a chord with me<br />
were that Government has failed to show any<br />
real leadership on energy matters, whilst “firing<br />
shots all over the place”; and also that he would<br />
like to have a meeting with Minister Amber<br />
Rudd, to “explain to her what Fabric First<br />
means.”<br />
Mr Pannell also shares my scepticism over the<br />
value of Energy Performance Certificates or<br />
EPCs; though while I believe they are not nearly<br />
specific enough in assessing the nature of the<br />
building fabric, his view is based on the fact<br />
that buildings are failing to reach their target<br />
standards.<br />
In his own recently constructed home there are<br />
apparently draughts coming from behind the<br />
electric sockets; while a later speaker<br />
expressed the view that because the UK’s<br />
climate is relatively mild we simply can’t be<br />
bothered to get our buildings right. If that is the<br />
case, achieving the Government’s commitments<br />
on carbon reduction really is going to be a<br />
problem.<br />
This disturbing perspective came from Gordon<br />
32<br />
Alistair Donn, Willmott Dixon and<br />
Kim Mead, Passive House Trust<br />
during the afternoon Q&A sessions<br />
Evans of the YOOP Architectural Practice who<br />
insisted that the Canadians build far better<br />
than us – in particular achieving very good<br />
airtightness and continuity of insulation –<br />
despite targeting less onerous U-values than<br />
are routinely used in the UK.<br />
Gordon Evans of the YOOP<br />
Architectural Practice<br />
considers that the Canadians<br />
build far better than us – in<br />
particular achieving very<br />
good airtightness and<br />
continuity of insulation –<br />
despite targeting less<br />
onerous U-values than are<br />
routinely used in the UK<br />
Although Gordon presented an overview of the<br />
Boxtree social housing development in Harrow,<br />
which has won many awards and so impressed<br />
the INCA judging panel I was on, he cited a<br />
variety of projects from around the globe that<br />
his practice has been involved on. Struck by the<br />
variety of building solutions they had used –<br />
including ICF and timber frame – I asked him<br />
during the Q&A session about the importance<br />
he and his colleagues put on local climate in<br />
relation to such decisions.<br />
His response was unambiguous, commenting<br />
on one which was internally insulated to<br />
counter the predominantly humid conditions,<br />
Kym Mead gave one of the afternoon’s best<br />
presentations on behalf of the PassivHaus Trust<br />
– those most airtight of buildings – and<br />
surprised many of us by reporting that the UK<br />
has only recently passed the 300 mark in terms<br />
of fully certificated projects. He did point out,<br />
however, that a block of flats counts as just one<br />
PassivHaus property.<br />
He also asserted that: “Done properly, a<br />
PassivHaus building will not suffer overheating<br />
in summer.”<br />
While the whole event was well worth the<br />
attention of those present – and it seemed<br />
many had decided not to attend due to the<br />
heightened security fears in London after the<br />
attacks in France – the case studies were<br />
probably of most value to delegates.<br />
Alasdair Donn of Wilmott Dixon for instance,<br />
talked about the Centre for Medicine at<br />
Leicester University which has been built to<br />
PassivHaus standards, and offered numerous<br />
insights into such issues as insulating bracketry<br />
and the need to carry out air leakage testing on<br />
zones as the structure progresses.<br />
We will cover some of the systems being shown<br />
in the a<strong>cc</strong>ompanying exhibition in our January<br />
edition.<br />
The Inmarsat Centre sits above Old Street<br />
Tube station on City Road and is an ideal<br />
facility for conferences of this size.
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Protect Membranes launches Party<br />
Wall Air Barrier Pack<br />
portable<br />
foundations for<br />
portable<br />
buildings<br />
Sale, UK – 12 November 2015 – Protect Membranes Limited have<br />
introduced the Protect Party Wall Air Barrier (“PWAB”) Pack, a<br />
completely air and watertight solution for sealing party walls to<br />
reduce heat loss to a minimum in timber frame construction.<br />
The pack, comprising a 300mm x 25m Protect party wall air<br />
barrier construction membrane with Protect Reinforced Universal<br />
Tape, has been specifically developed to overcome the problems<br />
of heat loss from party walls in timber frame buildings.<br />
The PWAB membrane is highly vapour permeable, allowing it to<br />
achieve the requirements for air sealing but still allowing water<br />
vapour to escape. Lightweight and easy to install, the Protect<br />
PWAB membrane is available in an optimum roll width, and the<br />
edges are sealed airtight using Protect Reinforced Universal Tape.<br />
“The Party Wall Air Barrier Pack is a welcome addition to<br />
Protect’s already comprehensive range of membranes for the<br />
construction and roofing markets,” said Christine Ryder, Product<br />
Manager for Protect.<br />
www.protectmembranes.com<br />
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modular buildings<br />
Leaves playground/car park surfaces undamaged<br />
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100% recycled materials<br />
www.jackpad.co.uk or call<br />
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<strong>MMC</strong> November 2015 33
Article ><br />
‘Traditional’ approach to island<br />
PassivHaus properties<br />
<strong>MMC</strong> Magazine’s Bruce Meechan reports on a substantial low energy development by one of the south-east of<br />
England’s largest housing associations.<br />
Many of our readers will be aware of<br />
the Isle-of-Wight’s desire to become<br />
a Zero Carbon beacon for other<br />
parts of the country – by maximizing the use<br />
of renewable energy sources as well as<br />
cutting usage across its properties – but the<br />
ambition has been brought a step closer<br />
thanks to the decision of Southern Housing<br />
Group to build 28 new homes to PassivHaus<br />
Standard. .<br />
Cameron Close in Freshwater on the island’s<br />
western side is a £4.2 million development of<br />
16 semi-detached family homes and a dozen<br />
sheltered apartments; built on a 1.5 acre site<br />
formerly o<strong>cc</strong>upied by an earlier retirement<br />
scheme belonging to the RSL.<br />
Interestingly, the development began its life<br />
being designed by PCKO Architects to satisfy<br />
the higher levels of the Code for Sustainable<br />
Homes, before Southern Housing Group’s<br />
Regional Manager viewed another PassivHaus<br />
project in Portland, Dorset and recognised the<br />
potential for doing the same at Cameron<br />
Close.<br />
As Alan Townshend, Development Director at<br />
Southern Housing Group, explained to <strong>MMC</strong><br />
Magazine: “We decided to make Cameron<br />
Close a PassivHaus development as it best<br />
meets the group’s sustainability objectives<br />
without the need to provide expensive<br />
renewable technology. We moved our current<br />
residents to a new modern sheltered housing<br />
scheme, Whitmore Court, that best met their<br />
needs and used the existing site to create<br />
those environmentally friendly family homes.<br />
“As part of our aim to provide sustainable<br />
tenures, the group is always looking at how we<br />
can improve the quality of the homes we<br />
provide, so not only does this ‘fabric first’<br />
approach provide an environmentally friendly<br />
solution for building these homes, it will also<br />
give the residents of Cameron Close<br />
significant and long-term savings on their<br />
energy bills.<br />
“When we decided to go down the traditional<br />
route rather than timber frame, Celcon was<br />
approached, and it was the company that<br />
suggested thin-joint construction as the best<br />
solution. Celcon was very helpful with<br />
technical guidance and providing training for<br />
the operatives from Stoneham Construction<br />
on the Isle-of-Wight who were going to lay the<br />
thin-joint system.”<br />
The exterior walls were finished with a<br />
proprietary render system applied to 230 mm<br />
of insulation, fixed over the 200 thick Celcon<br />
blockwork. This was parge coated on the inside<br />
in order to achieve an excellent level of<br />
airtightness – typically 0.<strong>48</strong> m3/m2/hr at 50<br />
Pascals. The contractor then formed a metal<br />
studded batten cavity behind a final lining of<br />
plasterboard which provides a service void.<br />
Also of major importance to controlling air<br />
leakage was the selection of triple glazed,<br />
aluminium clad windows from Munster Joinery,<br />
and exterior doors manufactured by Internorm.<br />
Then at first floor ceiling level, a polythene<br />
membrane was installed above the<br />
plasterboard soffit. Overall the su<strong>cc</strong>ess of all<br />
these measures is also the result of a<br />
‘PassivHaus Champion’ having been employed<br />
on site to monitor all of these details’<br />
execution; along with the multiple service<br />
penetrations.<br />
The ground floor construction features the use<br />
of a beam and block floor system, overlaid with<br />
250 mm of Kingspan Kootherm K3 insulation<br />
and then a further concrete slab which also<br />
helps add thermal mass to the living space.<br />
Of course the main idea of using such high<br />
levels of insulation in a PassivHaus<br />
construction is to keep energy usage down to a<br />
very low level; and often you will find properties<br />
just feature a wood burning stove to ‘top up’<br />
the heating on the coldest days. At Cameron<br />
Close, the solution chosen was to give every<br />
home a small combination boiler to not just<br />
supply the kitchen and bathroom with hot<br />
water, but also to heat a towel rail and a couple<br />
of radiators. One is in the hallway while another<br />
is situated in the lounge; offering visual<br />
comfort as much as physical warmth. Zehnder<br />
Comfoair MVHR units are also installed in every<br />
home to further reduce heat loss and ensure<br />
necessary air changes are achieved.<br />
Work actually started on site in early<br />
September 2013 with final planning permission<br />
having been granted in the previous December,<br />
before going through the OJEU tendering<br />
process. Alan recalled: “The tenders for<br />
building to PassivHaus standards actually came<br />
back higher than we had expected, but we had<br />
already secured HCA funding and the Isle-of-<br />
Wight Council also provided some finance to<br />
support the PassivHaus element to the build as<br />
it was in line with their Green Island agenda.<br />
“Our initial estimation is that the entire<br />
scheme could save up to £25,000 a year in<br />
energy costs, with some residents being able<br />
to save up to £900 in a three bedroom home.”<br />
The PassivHaus Institute has already precertified<br />
all fixtures and fittings to ensure that<br />
the required heating and primary energy limits<br />
are met; the homes are currently going<br />
through the PassivHaus certification process.<br />
Alan concluded saying: “If we were going to<br />
develop another PassivHaus project I think we<br />
might well use the thin-joint masonry again, as<br />
it proved very su<strong>cc</strong>essful, though we would<br />
probably revert to a traditional brickwork<br />
outer elevation as the render proved difficult<br />
to apply in the poor weather conditions<br />
suffered.”<br />
The properties are now the subject of post<br />
o<strong>cc</strong>upation monitoring using heat meters and<br />
other sensors.<br />
• Over the last 110 years, Southern Housing<br />
Group has become one of the largest<br />
housing associations in the south of<br />
England, housing more than 67,000<br />
residents, managing almost 30,000<br />
homes, employing nearly 900 people and<br />
working with more than 70 local<br />
authorities across the South East,<br />
including the Isle of Wight.<br />
• Our vision, ‘A business with social<br />
objectives’, draws on our history and<br />
traditions while recognising the need to<br />
change with changes in the housing<br />
sector.<br />
• Our social and economic regeneration<br />
work is undertaken to improve the lives of<br />
residents in the communities and<br />
neighbourhoods where we build and<br />
manage homes. It provides tangible<br />
evidence of our commitment to building<br />
sustainable communities.<br />
• Southern Housing Group is a member of<br />
the g15, which represents London's 15<br />
largest housing associations. The g15<br />
houses one in ten Londoners and builds a<br />
quarter of London's new homes. We are<br />
working to solve the housing crisis by<br />
delivering good quality, affordable homes<br />
of all types. To find out more about the<br />
g15's work please visit g15london.org.uk<br />
34
“As part of our aim to provide<br />
sustainable tenures, the group is always<br />
looking at how we can improve the<br />
quality of the homes we provide, so not<br />
only does this ‘fabric first’ approach<br />
provide an environmentally friendly<br />
solution for building these homes, it will<br />
also give the residents of Cameron Close<br />
significant and long-term savings on<br />
their energy bills.”<br />
Alan Townshend, Development Director at Southern Housing Group<br />
<strong>MMC</strong> November 2015 35
Article ><br />
ErP means level playing field for heating<br />
Mitsubishi Electric has produced a free, CPD-a<strong>cc</strong>redited guide to the new Energy Related Products Directive or ErP<br />
(2009/125/EC), which is a key part of the European Union’s drive to encourage consumers to use more energy<br />
efficient products.<br />
To highlight the requirements under ErP<br />
the company has also released a short<br />
video which explains how the Directive<br />
is designed to help phase out lower<br />
performing products whilst having a positive<br />
impact on the emissions levels across Europe<br />
and increase the share of renewable energies<br />
by 20 per cent.<br />
The ErP Directive, which came into force at the<br />
end of September 2015, now means that<br />
commercial and residential heating products<br />
will need to display an energy label, so that<br />
consumers can quickly understand the energy<br />
efficiency of the products they purchase.<br />
A similar market transformation strategy has<br />
already proved highly su<strong>cc</strong>essful with consumer<br />
goods such as fridges and freezers, where it is<br />
now very rare to find anything below an A rated<br />
product available on the high street.<br />
“There are two parts to the ErP strategy which<br />
affect both manufacturers and installers and<br />
everyone involved needs to understand how<br />
this will change the heating market”, explains<br />
Max Halliwell, who fronts the video on behalf of<br />
the company.<br />
Firstly, the ErP requires manufacturers to<br />
produce energy-using products that meet<br />
stringent minimum performance standards.<br />
And secondly, these products must be clearly<br />
labelled using a standard methodology so that<br />
consumers can quickly understand the energy<br />
efficiency of the products they purchase.<br />
These labels will show the efficiency ranging<br />
from the most efficient A++ to the least<br />
efficient G and will be clearly marked with<br />
coloured bars; from green (the most efficient)<br />
all the way down to red (least efficient).<br />
36<br />
The details on the label will identify the<br />
efficiency band for heating, and where relevant,<br />
hot water production and where relevant, noise,<br />
emissions and power consumption.<br />
“For heat pumps they will also indicate the<br />
three different climate zones within Europe<br />
which is important<br />
here because the<br />
UK is split<br />
between all three<br />
of these zones”,<br />
adds Halliwell.<br />
“We feel that<br />
this is now<br />
levelling the<br />
playing field for<br />
heating<br />
products which<br />
will allow<br />
consumers to<br />
see exactly<br />
how energy<br />
efficient the types of<br />
heating they choose are”.<br />
ErP is a significant piece of legislation that will<br />
have a major impact on the sale and use of<br />
heating systems in the UK. As such, the<br />
requirements of ErP is already being embedded<br />
into legislation on the energy efficiency of<br />
buildings and as incentive schemes for<br />
renewable technologies.<br />
In order to apply for Renewable Heat Incentive<br />
(RHI) payments, heating systems will now<br />
needs to comply with the Microgeneration<br />
Certification Scheme (MCS), which sets<br />
industry standards for products used to<br />
produce heat from renewable sources.<br />
In May 2015, the MCS published a new seasonal<br />
coefficient of performance (SCOP) calculator. It<br />
also updated its Installation Standard for heat<br />
pumps as a direct result of the introduction of<br />
ErP. The introduction of this SCOP calculator<br />
will enable certification bodies to use a<br />
standard method based on ErP to establish<br />
whether a heat pump is compliant.<br />
“This is important because in the past, the<br />
efficiency of a heating system was based on<br />
what is known as the coefficient of<br />
performance or COP”, explains<br />
Halliwell, “but this<br />
shows a single point in<br />
time, which is never a<br />
good indication on how<br />
efficiently it will perform<br />
all year round, whereas<br />
SCOP shows the<br />
performance across the<br />
different seasons and<br />
gives a much more<br />
a<strong>cc</strong>urate indication of<br />
efficiency”.<br />
The dedicated video can be<br />
viewed at the company’s<br />
YouTube Channel and<br />
further information on the<br />
entire range of A++ heat pumps can be found<br />
on the dedicated Youtube channel at<br />
youtu.be/4tzKoyzRMOU or at ecodan.co.uk.<br />
The CPD Guide covers both main parts of the<br />
ErP: the EcoDesign regulations and the Energy<br />
Labelling regulations. The guide explains how<br />
the labelling is designed to help businesses and<br />
homeowners understand the benefits of each<br />
technology and focuses on the importance of<br />
ErP in relation to legislation such as the<br />
Renewable Heat Incentive (RHI).<br />
Visit library.mitsubishielectric.co.uk and click<br />
on CPD Guides to download a version.
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or visit ecodanerp.co.uk/homeowner<br />
Ecobuild supports delivery of infrastructure revolution<br />
with new ice partnership and zone for 2016<br />
A new partnership between Ecobuild, the UK’s leading event for the construction industry, and the Institution of Civil Engineers<br />
(ICE) has been launched today ahead of the 2016 Ecobuild conference. The partnership will focus around a major new conference<br />
and exhibition centre – The Infrastructure Revolution Hub – which will enable industry to come together and discuss ways it can<br />
maximise the opportunity for growth, following Government’s commitment to infrastructure as key economic driver.<br />
At the heart of the Hub will be a large<br />
conference area which will debate the<br />
key issues for the infrastructure<br />
sector across the three days of Ecobuild. The<br />
Hub will also feature products and services<br />
key to this growth sector and the ICE genius<br />
networking bar, making it one of the key<br />
destinations at Ecobuild for infrastructure<br />
professionals looking to make connections<br />
with the people that matter. .<br />
TThe infrastructure seminars held in the<br />
Infrastructure Revolution Hub will feature the<br />
UK’s leading contractors and industry experts.<br />
With a mix of keynote speakers and panel<br />
sessions, the seminars will focus on future<br />
challenges, opportunities and global best<br />
practice. Discussions will cover three overall<br />
themes - ‘Creating the infrastructure of the<br />
future’, ‘Small cities’, and ‘Modelling climate<br />
change’, including decarbonising urban<br />
infrastructure, energy generation, unlocking<br />
private capital, bespoke planning, collaboration<br />
opportunities, modelling demand of growing<br />
populations, and flood risk management and<br />
mitigation.<br />
The partnership between ICE and Ecobuild<br />
follows Government’s announcement of a<br />
National Infrastructure Commission – an<br />
independent body that will enable longer term,<br />
strategic decisions to be made on<br />
infrastructure. Government has also committed<br />
to investing £100 billion in new infrastructure<br />
projects in this parliament. The industry has a<br />
crucial part to play and the new Infrastructure<br />
Revolution Hub will bring the key players<br />
together to drive forward change and<br />
innovation.<br />
Leading architect and member of the new<br />
National Infrastructure Commission, Sadie<br />
Morgan, will also be delivering a session on day<br />
two of the Ecobuild 2016 conference.<br />
Nathan Baker, ICE’s Director of Engineering<br />
Knowledge, said: “The societal benefit of<br />
effectively procured and managed<br />
infrastructure is immense. The need for<br />
increased collaboration, innovation and<br />
managing risk has never been higher than<br />
today. To create sustainable infrastructure, it is<br />
essential that we embrace new methods of<br />
working, increase the use of technology and<br />
new materials and develop a highly skilled,<br />
diverse workforce. The new Hub will help to<br />
bring these challenges and opportunities to the<br />
fore and encourage positive action to be<br />
taken.”<br />
Martin Hurn, Ecobuild Event Director<br />
commented: “The infrastructure sector is a key<br />
driver of construction industry growth with the<br />
Government putting a major focus on delivery<br />
of infrastructure pipeline projects, and the<br />
recent strong output figures boosted by the<br />
new Commission pointing to sustained<br />
performance. The new Hub will enable the<br />
sector to come together in 2016 and have the<br />
conversation around the shared agenda for<br />
delivery of the Infrastructure Revolution.”<br />
Ecobuild 2016 takes place at ExCeL,<br />
London from 8th to 10th March<br />
2016. For further information about<br />
Ecobuild 2016 please visit<br />
www.ecobuild.co.uk<br />
<strong>MMC</strong> November 2015 37
Article ><br />
Shackerley’s engineered stone façades<br />
shape up beautifully at Kew Bridge West<br />
Shackerley has demonstrated the extraordinary design potential and versatility of its Sureclad ® ventilated cladding<br />
offer by supplying an innovative engineered stone façade system for a challenging installation at Kew Bridge West,<br />
an exclusive development of 336 luxury apartments in North London.<br />
Two circular towers presented a major technical<br />
challenge for Shackerley and Stanmore<br />
Curved facade panels have been cut from solid blocks of engineered stone and specially prefabricated<br />
Prefabricated engineered stone façades<br />
Shackerley has supplied 2400m 2 of fully<br />
prefabricated Sureclad ® engineered stone<br />
cladding for the lower storeys of the nine<br />
apartment buildings that form this stunning<br />
complex, designed by Stockwool and developed<br />
by St James, part of the Berkeley Group.<br />
The engineered stone, in a natural limestone<br />
colourway and honed finish, provides a<br />
premium quality aesthetic at eye level<br />
throughout the development, contrasting with<br />
the lighter coloured insulated render of the<br />
upper storeys.<br />
Large format curved panels<br />
Two of the buildings feature circular towers<br />
calling for smooth and flawless rounded<br />
façades, which presented Shackerley and Kent<br />
based specialist façade installation contractor<br />
Stanmore with a significant technical challenge.<br />
Shackerley’s Sureclad ® Hang On system had to<br />
be customised to cater for large format curved<br />
panels, cut to a radius from solid blocks of<br />
engineered stone. Additional challenges<br />
included the design of elegantly faceted<br />
façades, using more traditionally formatted flat<br />
panels, to clad curved elevations of adjacent<br />
buildings, designed to reflect the ‘horseshoeshaped’<br />
design of the complex.<br />
Close collaboration<br />
Because of the very individual nature of this<br />
project, and in particular the use of curved<br />
large format engineered stone, Shackerley and<br />
Stanmore worked very closely together to<br />
ensure the developer’s requirements were met.<br />
Bespoke solutions were required at every stage,<br />
from the design of the Sureclad ® façades to the<br />
meticulous scheduling and non-standard<br />
palletisation of the prefabricated system for<br />
safe delivery to site. To ensure the installation<br />
went smoothly, Stanmore’s installers also<br />
visited Shackerley to receive expert training in<br />
the use of the Sureclad ® system.<br />
Testing to NHBC criteria<br />
As this was the first time that the Sureclad ®<br />
system had been used in conjunction with<br />
curved engineered stone panels, the two<br />
companies arranged for the bespoke Sureclad ®<br />
system to be tested at VINCI Technology Centre<br />
UK where it was shown to meet all NHBC<br />
criteria.<br />
Su<strong>cc</strong>essful installation<br />
Stanmore Commercial Director Peter Baker<br />
said: “We were responsible for delivering all the<br />
external façades, curtain walling, doors,<br />
windows and other external finishes on this<br />
project but the engineered stone cladding was<br />
by far the most highly valued element of the<br />
job. Close collaboration with our supplier was<br />
absolutely crucial. We hadn’t worked with<br />
Shackerley or its Sureclad ® façade system<br />
before, and it was also the first time that either<br />
party had worked with curved engineered stone<br />
panels, so there were many challenges to<br />
overcome.<br />
“However, by meticulously planning and<br />
modelling the installation and working hand in<br />
hand with Shackerley’s technical team, we<br />
achieved superb results for our client. The<br />
overall experience was very positive and we’re<br />
looking forward to working on other Sureclad ®<br />
projects in the future.”<br />
Award winning development<br />
Construction Director at St James, Brian<br />
Paterson, commented: “It was only when we<br />
came to value engineer the Kew Bridge West<br />
project that Shackerley’s system was brought<br />
to our attention. As a result of switching the<br />
engineered stone specification to Sureclad ® ,<br />
we’ve undoubtedly benefitted from a more<br />
flexible and lighter façade solution than<br />
originally planned and, most importantly, from<br />
38
Faceted cladding was installed to reflect the horseshoe shape of the development<br />
very substantial cost savings, whilst still<br />
achieving our architects’ original design<br />
intention.<br />
He concluded: “We’re delighted with the results<br />
and the project has received very favourable<br />
feedback from colleagues throughout the<br />
Berkeley Group. The quality of Kew Bridge<br />
West has also been recognised within the wider<br />
industry, and in October, St James received an<br />
NHBC Seal of Excellence Award for achieving<br />
the highest standards in house building at this<br />
prestigious development.”<br />
“...As a result of switching<br />
the engineered stone<br />
specification to Sureclad ® ,<br />
we’ve undoubtedly<br />
benefitted from a more<br />
flexible and lighter façade<br />
solution than originally<br />
planned...”<br />
Shackerley’s engineered stone façades clad<br />
the lower storeys of the development<br />
Sureclad ® versatility<br />
Shackerley has su<strong>cc</strong>essfully clad hundreds of<br />
buildings, including many high profile<br />
developments, with its Sureclad ® ceramic<br />
granite cladding façade systems and is the<br />
clear market leader in the UK. Highly<br />
specialised manufacturing facilities at its ISO<br />
9001 certified factory include bespoke diamond<br />
tipped undercut drilling machines that provide<br />
recesses for undercut anchors that are used to<br />
prefabricate every Sureclad ® façade panel. As<br />
the Kew Bridge West development shows, these<br />
facilities are now being employed to<br />
prefabricate large format engineered stone,<br />
including curved façade panels, in exactly the<br />
same way, for installation as part of a Sureclad ®<br />
system.<br />
For further details on the Sureclad ® system<br />
please contact Shackerley on 0800 783<br />
0391 or visit www.shackerley.com<br />
Kew Bridge West, a stunning award winning development comprising nine individual apartment buildings<br />
<strong>MMC</strong> November 2015 39
The Great Debate – Is Offsite Construction<br />
the answer to the delivery challenge faced<br />
by the UK Construction Industry?<br />
With turnover predicted to reach £7billion by 2018 has the offsite construction sector finally found a place on the<br />
mainstream construction agenda? Could it indeed make the difference to the UK construction industry in its quest<br />
to deliver 200,000 new homes per year as well as new schools, student a<strong>cc</strong>ommodation, and commercial buildings?<br />
Mike Stevenson<br />
The answer to these and other questions<br />
were the topic of two very lively<br />
debates at the recent inaugural offsite<br />
construction show. The debates were hosted<br />
by The Fabric First Academy, for whom Mike<br />
Stevenson Development of founding partner<br />
Sidey set the scene..<br />
“Being at an offsite construction show seemed<br />
to us to be the ideal opportunity to debate the<br />
merits of offsite construction in the context of<br />
the wider industry, the challenges it faces, and<br />
the positive benefits it can deliver to the UK<br />
construction industry as it seeks to deliver<br />
unprecedented levels of new homes, student<br />
a<strong>cc</strong>ommodation buildings, schools and<br />
commercial buildings”.<br />
“What we didn’t want was simply advocates of<br />
offsite construction saying how good it was – in<br />
fact we wanted the opposite. We wanted to find<br />
out what a cross section of industry people<br />
really thought about it; I think it is fair to say<br />
that those who attended didn’t go home<br />
disappointed, and hopefully they went away<br />
with more information and knowledge than<br />
they came with”.<br />
“Indeed knowledge is a great place to start. We<br />
asked the question as to why – although the<br />
offsite sector is on course to hit £7billion by<br />
2018 – there was still a resistance or reluctance<br />
to engage with this method of construction<br />
amongst so many”.<br />
“The view from the panel was that there was a<br />
real knowledge gap when it came to offsite<br />
methods and understanding the achievable<br />
benefits of building this way. Starting right at<br />
the beginning with architecture and design it<br />
was recognised that offsite did not form a big<br />
enough part of their learning, and very few<br />
architect’s practices actually design with offsite<br />
in mind from the outset; more so the appointed<br />
contractor looks at already agreed designs and<br />
only then see if offsite construction methods<br />
might be suitable to bring the scheme to life”.<br />
“This is a really key point; with so many sites<br />
now in tight inner city and urban locations the<br />
restrictions are such that building traditionally<br />
is often at best extremely difficult &<br />
problematic but at times just unfeasible. It is<br />
these restrictions – unaddressed at the outset –<br />
which can lead to costs running away from the<br />
agreed budget, and delivery times slipping<br />
away”.<br />
“For clients facing the twin pressures of budget<br />
constraint and needing to deliver quickly<br />
budget slippage is simply not a<strong>cc</strong>eptable, and<br />
neither is late delivery with the demands upon<br />
them to provide a<strong>cc</strong>ommodation for a growing<br />
population in need of their support. Indeed it<br />
is the very essence of what offsite construction<br />
can bring – cost and delivery predictability<br />
which is seeing more and more people sit up<br />
and take notice”.<br />
“Stemming further from this was a realisation<br />
that the often spoken about labour and skills<br />
shortages are now really starting to bite, hitting<br />
not only on site, but actually in roles which are<br />
responsible for the design and development<br />
stages of building in the first place. Again, the<br />
same message - there is a knowledge gap to be<br />
filled as well as a skills gap. And talking of<br />
skills, a<strong>cc</strong>ording to the panel the UK<br />
construction industry is facing a loss of<br />
700,000 construction personnel over the next<br />
five years through entirely natural processes”.<br />
“The view was that delivering through offsite<br />
construction can reduce the labour<br />
requirement on any contract by up-to 25%, a<br />
number which could rise further as more<br />
construction is done this way”.<br />
“But perhaps the biggest debate was why does<br />
there appear to be such a resistance at<br />
constructor level to engaging with offsite and<br />
then seeing it through to delivery? Clearly<br />
40
there are many of the major construction<br />
companies now exploring offsite fully as they<br />
start to understand the benefits of cost<br />
predictability and delivery against those of<br />
traditional building methods and the need to<br />
guarantee their clients exactly what they ask<br />
for to an a<strong>cc</strong>eptable standard, on time and to<br />
budget”.<br />
“Coming out loud and clear from the debates<br />
was the on-going disconnect between design<br />
teams and construction teams. Too few of the<br />
buildings which are developed for offsite<br />
construction actually reach the site stages still<br />
as offsite manufactured schemes; yet the<br />
implications of this have been proven to be<br />
significant – with disappointed clients being<br />
upper most”.<br />
“Undoubtedly design teams are increasingly<br />
starting to work collaboratively with the offsite<br />
sector to specify developed solutions which will<br />
deliver ‘as built’ buildings which perform as<br />
they were specified and designed to do in the<br />
first place, thus closing the renowned<br />
performance gap of circa 20%. This is in<br />
addition to projects delivered on time and to<br />
budget”.<br />
“However contractors and developers seem to<br />
retain a very different view in too many<br />
instances, and see their role as being to ‘deconstruct’<br />
the design solutions; to break them<br />
down into their individual components for<br />
procurement purposes ‘because it is cheaper’.<br />
This is entirely counter to the principles of<br />
offsite construction, which is all about solutions<br />
that ensure all the components work together,<br />
including the key joints and interfaces, to<br />
guarantee the performance of the structure.<br />
Who looks at a car and says right I can build<br />
that cheaper by sourcing all the components<br />
separately. It may look like the original design<br />
but it’s very unlikely to perform as well as the<br />
one sourced from the manufacturer”.<br />
“This was an emotional area of debate, and the<br />
general feeling was that construction is not<br />
modern enough in its thinking; it is not<br />
collaborating enough; there’s too much conflict;<br />
the answers lay in the supply chain;<br />
constructors need to embrace working with the<br />
supply chain as a real positive”. “Clearly this is<br />
a debate which is going to run and run”.<br />
Mike Stevenson is Development Director of<br />
offsite and new-build fenestration specialists<br />
Sidey and founding partner of The Fabric First<br />
Academy. The panel of speakers consisted of<br />
Darren Richards of Cogent Consulting who<br />
chaired the debate, Robert Clarke Fusion<br />
Building Solutions, Jim Roach ARV Solutions,<br />
John Skivington LHC, Paul Neep Architype<br />
Architects, Paul Wright Tremco Illbruck and Dr<br />
Robert Hairstans Institute for Sustainable<br />
Construction.<br />
The Fabric First Academy<br />
www.fabricfirstacademy.co.uk<br />
Sidey www.sidey.co.uk<br />
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<strong>MMC</strong> November 2015 41
Article ><br />
Value engineering –<br />
what’s it all about?<br />
As the construction industry strives to provide the optimum building solution, just how can companies today<br />
differentiate themselves and ensure they are offering best value?<br />
Lincoln gateway<br />
Steve Thompson, Managing Director of<br />
light steel frame manufacturer, EOS<br />
Facades explains how they are using<br />
value engineering and Design for Manufacture<br />
and Assembly (DfMA) to meet the demands of<br />
today’s construction industry.<br />
Value Engineering – What is it?<br />
Today’s customers are savvier, more<br />
commercially aware and they expect more for<br />
their money. As manufacturers and service<br />
providers, we need to react and meet this<br />
demand, or risk losing out.<br />
But before we can do this, we need to<br />
understand what value really is.<br />
Assessing best value depends on the objectives<br />
set - speed of construction, build costs or the<br />
development of a sustainable, energy efficient<br />
building - or perhaps a combination of all.<br />
Adopting a ‘one system fits all approach’ will<br />
not necessarily deliver best value. It is not<br />
about economies of scale but it is about an<br />
optimised approach - working with the client to<br />
select the right solution, at the right price, to<br />
deliver the right performance.<br />
Adding Value: Design for Manufacture and<br />
Assembly<br />
As a manufacturer of steel solutions, EOS<br />
Facades take full advantage of offsite<br />
manufacturing techniques by adhering to<br />
Design for Manufacture and Assembly (DfMA)<br />
protocols. DfMA is now recognised as the<br />
foundation for concurrent engineering<br />
processes to streamline and fully optimise the<br />
structure. The process aids the building design<br />
process and helps to identify, quantify and<br />
eliminate waste or inefficiency where possible.<br />
At EOS Facades we pride ourselves on driving<br />
quality through precision manufacturing whilst<br />
delivering a<strong>cc</strong>urate results on time and on<br />
budget.<br />
We have taken steps to ensure that DfMA is<br />
integrated throughout the design and<br />
manufacturing process. We have made<br />
considerable investment in developing<br />
technology to aide specification and design. We<br />
are totally committed to working with our<br />
clients on product and service innovations to<br />
help them gain a competitive advantage in the<br />
marketplace – delivering cost and time<br />
efficiencies.<br />
The EOS manufacturing facility is a 40,000 sq<br />
ft operation that houses state-of-the-art<br />
machinery and technology providing offsite<br />
systems and solutions that meet the needs of<br />
our customers. Our manufacturing facility is<br />
well equipped to cater for the demands of<br />
offsite construction and precision engineering.<br />
Our sophisticated roll-forming machines have<br />
embedded framing technology that enables<br />
production of self-jigging framing components<br />
that are ready for assembly, eliminating the<br />
need to manually cut onsite.<br />
All of our products are manufactured under<br />
strict quality management control which is fully<br />
compliant with BS EN ISO 9001:2008. Our<br />
a<strong>cc</strong>redited quality management systems and<br />
procedures eradicate onsite variability and<br />
ensure life time ‘in service’ performance and<br />
durability.<br />
Adding Value: Software and Building<br />
Information Modelling<br />
Precision built offsite products require the<br />
application of leading-edge technology and<br />
contemporary manufacturing processes. We<br />
have invested substantially in the latest<br />
software and hardware systems in steel frame<br />
42
production. Our systems combine the latest E-<br />
Frame technology platform with proven<br />
assembly processes, providing fully framed<br />
panels that do not require jigging.<br />
The Shard<br />
Sophisticated software transfers building<br />
design information directly to our production<br />
plant where we are able to manufacture to<br />
a<strong>cc</strong>uracies that exceed construction industry<br />
norms. Once the panels have been designed<br />
using our 3D Tekla modelling software, they are<br />
directly uploaded to the roll-forming machines,<br />
using a bespoke CAD/CAM interface, where<br />
they are produced to exact dimensions using<br />
CNC technology. Each stud is identified with an<br />
inkjet printer to match the assembly drawing<br />
and every frame has an identification label<br />
attached. This identifies the project, frame<br />
number, order number and site location on the<br />
GA site drawings so they can be positioned<br />
quickly to their onsite location.<br />
Adding Value: Product<br />
Product quality is essential. EOS only use<br />
minimum S390Nmm2 G275gsm steel (higher<br />
grades and coatings on request). By only using<br />
steel with a protective coating and design<br />
detailing that eliminates prolonged exposure,<br />
EOS are confident in the durability of our<br />
systems. Research has shown in these<br />
conditions coated steel has a potential life of<br />
over 1,000 years.<br />
The team at EOS support key industry<br />
standards and strive to exceed expectations on<br />
reliability and delivery. All of our products are<br />
manufactured to rigorous quality standards<br />
which are fully compliant with the Construction<br />
Products Regulations - EN 1090-1: 2009 + AL:<br />
2011. Our quality management systems are BS<br />
EN ISO 9001: 2008 registered.<br />
Victoria Halls London<br />
Adding Value: Cost<br />
We offer all-inclusive fixed price packages that<br />
are uniquely supplied with proprietary brackets<br />
and fixings required. All Double Studs/Opening<br />
Jambs/Lintels and Sills will be dispatched from<br />
our factory preassembled. This is a flexible<br />
service and should you require the product to<br />
arrive unassembled, EOS will pre-punch in the<br />
factory, ghost assemble and supply, together<br />
with all the necessary screws and special drill<br />
bits, for assembly and installation onsite.<br />
Adding Value: People<br />
EOS Facades are constantly striving to improve<br />
the way we work and the resulting benefits are<br />
passed onto our customers. Research &<br />
Development is a core focus of our business<br />
and it is not just down to one specific team, at<br />
EOS everybody is encouraged to put<br />
recommendations forward, whether this is a<br />
process or an alteration to a product – that way<br />
every part of our business can be enhanced.<br />
EOS also offer a total partner solution including<br />
application consultancy, structural design<br />
support and value engineering, as well as<br />
quality manufacturing.<br />
To meet the demands, we need people to make<br />
the change happen.<br />
Now the construction industry is starting to<br />
recognise the shift in needs of the client,<br />
manufacturers must ask themselves, are they<br />
well equipped to meet demands or will they risk<br />
losing out?<br />
For more information on EOS Facades’ products<br />
and services visit: www.eos-facades.co.uk<br />
Adding Value: Knowledge Sharing<br />
In a bid to share their extensive knowledge,<br />
EOS Facades are offering a series of CPD<br />
sessions, designed to highlight the various light<br />
gauge steel solutions available, and explain how<br />
these can be applied in real life scenarios.<br />
The hour long seminars will cover a wide range<br />
of steel solutions and services including:<br />
• Cold Formed Sections<br />
• SFS Infill Systems<br />
• SFS Onsite Stud and Track<br />
• SFS Offsite Pre-assembled<br />
• Other applications – including LBS, Lattices<br />
and Cassettes<br />
• Design<br />
• Partnering<br />
• Examples of Best Practice<br />
These CPD sessions could not be more<br />
convenient – an EOS Facades technical<br />
representative will come directly to you and the<br />
seminars are completely free of charge. Get<br />
involved and start talking about light gauge<br />
steel!<br />
To request your CPD session, simply contact<br />
Thomas Elliott, EOS Facades Technical Sales<br />
Manager on thomas@eosuk.org or<br />
07528 364 581.<br />
www.eos-facades.co.uk<br />
<strong>MMC</strong> November 2015 43
Article ><br />
Medite & Smartply set sights<br />
on off-site construction<br />
Wood panels are the natural choice for developers and house builders looking to utilise the time, cost and quality benefits of offsite<br />
construction. In particular, engineered wood panels offer specifiers, timber frame manufacturers and contractors the<br />
enhanced flexibility, improved quality and superior safety to ensure the industry continues to build for the future.<br />
Leading manufacturers of engineered<br />
wood panels, Medite and SmartPly offer a<br />
wide range of high performance products<br />
for wall, floor and roof applications. From the<br />
breathable Medite Vent to the new SmartPly<br />
VapAirTight with integrated vapour control and<br />
air barrier properties – Medite and SmartPly<br />
provide high performance, environmentally<br />
friendly and easy to install products that are<br />
perfect for modern construction.<br />
Lessons in performance<br />
At the University of East Anglia’s (UEA)<br />
landmark development The Enterprise Centre,<br />
over 11,000m2 of SmartPly OSB3 was supplied<br />
for use in the structural timber frame.<br />
Manufactured using zero added formaldehyde,<br />
SmartPly OSB3 met the client and contractor’s<br />
strict requirements for proven performance<br />
and extremely low environmental impact.<br />
The build-up of the wall panels featured 18mm<br />
taped SmartPly OSB3 on the inside for racking<br />
and airtightness, followed by a 140mm cellulose<br />
insulated structural stud, a thermal break<br />
cavity filled with cellulose insulation and a<br />
second 63mm insulated stud.<br />
For projects where flame retardance is a<br />
prerequisite, SmartPly has developed SmartPly<br />
FR OSB3. Manufactured using Zeroignition<br />
Solution, a water based, eco-friendly, fire<br />
retardant, this penetrates into the wood<br />
strands to ensure best in class fire performance<br />
whilst fully maintaining structural integrity.<br />
At the construction of The Edge – a sevenstorey,<br />
timber frame a<strong>cc</strong>ommodation building<br />
for students of John Moores University and<br />
University of Liverpool – SmartPly FR OSB3 was<br />
specified over conventional post-treated wood<br />
panels due to its guaranteed consistency and<br />
excellent flame retardant properties.<br />
The future of OSB<br />
Environmental credentials are now a crucial<br />
requirement in modern construction. With<br />
Passivhaus and low energy construction<br />
growing in popularity, SmartPly developed a<br />
structural panel that meets these requirements.<br />
The new SmartPly VapAirTight OSB panel, for<br />
which a patent is pending, is specifically<br />
engineered to deliver outstanding levels of<br />
airtightness and vapour control.<br />
Each panel features alternating layers of wood<br />
strands coated with a high quality<br />
formaldehyde-free resin and wax binder system<br />
to deliver outstanding levels of airtightness. A<br />
specialist coating is then applied to ensure<br />
vapour resistance and provide a premium<br />
performance OSB solution for super-insulated<br />
and passive buildings and enabling the<br />
elimination of a traditional additional vapour<br />
control membrane.<br />
Breathe more easily<br />
When designing and building timber frame<br />
structures, the risk of interstitial condensation<br />
is a key consideration as it can lead to mould<br />
growth, health issues and can even compromise<br />
structural integrity. Medite Vent meets the<br />
need for a breathable panel for use in external<br />
sheathing for all types of timber frame<br />
construction, supporting a well-ventilated<br />
building design.<br />
Combining high racking strength in excess of<br />
Category 1 requirements with excellent vapour<br />
permeability and high weather resistance,<br />
Medite Vent is an ideal choice for the outer<br />
layer in ‘diffusion open’ wall and roofing<br />
applications. Medite Vent is also produced<br />
using zero-added formaldehyde and carries the<br />
CE mark in a<strong>cc</strong>ordance with EN 13986 – making<br />
it a sustainable, reliable and high performance<br />
choice for low energy construction projects.<br />
Engineered wood panels deliver quality,<br />
performance and durability for a wide range of<br />
structural and non-structural applications. The<br />
specialist ranges of high performance and<br />
environmentally friendly systems from<br />
SmartPly OSB and Medite MDF make them the<br />
natural choice for forward-thinking architects,<br />
specifiers and contractors.<br />
www.coilltepanelproducts.com<br />
44
Celotex launches concrete soffit liner insulation solution<br />
Insulation specialist Celotex has once<br />
again demonstrated its innovative<br />
credentials with the launch of Celotex<br />
SL5000. Specifically targeted at<br />
concrete soffit liner applications,<br />
Celotex SL5000 is an exciting new<br />
addition to the company’s ‘5000’<br />
series premium performing product<br />
range.<br />
Designed for concrete soffit liner<br />
applications, Celotex SL5000 is a<br />
premium performance thermal<br />
insulation board combining premium<br />
performance PIR insulation bonded to<br />
6mm calcium silicate, providing<br />
additional fire performance. With a<br />
super low lambda value of 0.021W/mK,<br />
SL5000 ensures Regulatory<br />
compliance is achieved with minimal<br />
insulation thickness.<br />
Celotex SL5000 provides on-site<br />
benefits too, significantly reducing<br />
installation times due to the insulation<br />
and calcium silicate being supplied as<br />
one product. Delivering greater impact<br />
resistance compared to exposed<br />
insulation systems, SL5000 provides a decorative finish with no need for on-site decorating.<br />
“As an innovator within the insulation sector, we are always looking to develop solutions for the most challenging applications,” said Paul<br />
Evans, Head of Marketing at Celotex. “Celotex SL5000 further enhances our range of solutions and achieves Building Regulation targets with<br />
thinner solutions than many other insulation materials.”<br />
Offering excellent sustainable qualities, the insulation component of SL5000 is A+ rated when compared to the BRE Green Guide and Class O<br />
fire rated.<br />
Available in thicknesses from 86mm to 106mm and a board size of 1200mm x 2400mm, Celotex SL5000 can be installed by direct fixing to<br />
the concrete soffit or by indirect fixing via treated timber battens. The Celotex Technical Centre are on hand to answer and technical queries<br />
for existing or future projects. Visit celotex.co.uk for contact information.<br />
Celotex has a long and proud history of continuing to develop new and innovative solutions. With a clear focus on maximising thermal<br />
efficiency with thinner solutions, the new Celotex SL5000, gives specifiers a solution for concrete soffit liner applications.<br />
Knauf Spray Plaster keeps boutique motel to tight schedule<br />
www.celotex.co.uk<br />
Ready Mixed Spray Plaster developed by Knauf delivered the finest finishes on the<br />
fast-track construction programme to develop a major new hotel in the centre of<br />
London - Motel One London-Tower Hill.<br />
“The major advantage with these products is the speed at which you can apply them<br />
– three or four times faster than manual application,” said Matt Smith, who runs the<br />
specialist subcontractor Spray Plastering Specialists appointed by McAleer & Rushe.<br />
“We have far greater control because there are fewer people on site. We have a team<br />
of just three people and we can do 30 rooms a week. We have one guy working ahead<br />
of us filling and jointing and two people spraying plaster,” he said.<br />
Knauf’s range of Ready Mixed Spray Plasters enable up to 1,000m2 per week can be<br />
finished by a three man gang, while surfaces can be emulsioned within 24 to <strong>48</strong><br />
hours, so the plaster can be applied by the same teams applying the paint finishes.<br />
They offer a range of finishes, including flat and smooth, textured, leathered, combed<br />
or rollered.<br />
www.knauf.co.uk<br />
<strong>MMC</strong> November 2015 45
Product News ><br />
First Street in<br />
Manchester gets a<br />
Home<br />
Prater has recently delivered the<br />
external cladding and roofing works at<br />
independent film hub and visual arts<br />
centre, Home, in First Street,<br />
Manchester. Completed in April 2015,<br />
Home forms part of a 20 acre<br />
development in the heart of<br />
Manchester city centre.<br />
Performing for zero carbon timber homes<br />
An example of how timber is playing a major role in the UK’s first eco-town NW Bicester is a<br />
collaboration between Stewart Milne Timber Systems and the A. Proctor Group, which is<br />
providing high thermal performance using off-site modules. The first phase of A2Dominion’s<br />
development in the new town is a project to deliver 393 homes with a ‘true zero carbon’<br />
rating and offering energy efficient, good quality, affordable housing.<br />
The A. Proctor Group has supplied its Roofshield and Reflectashield TF 0.81 membranes for<br />
pre-assembled modules. These pre-assembled elements enable a pair of semi-detached<br />
homes to be weathertight, secure and fully insulated within 72 hours.<br />
Roofshield is an air and vapour permeable roofing<br />
underlay which provides a high degree of water<br />
resistance; the product provides the most costeffective<br />
solution to controlling interstitial<br />
condensation in a pitched roof. Reflectashield TF 0.81 is<br />
a vapour permeable low emissivity membrane for use<br />
externally on timber frame buildings.<br />
www.proctorgroup.com<br />
Making light work of brick soffits<br />
Creating flawless brick-faced soffits and lintels has<br />
now become much simpler and quicker, thanks to a<br />
new lightweight stainless steel-based system<br />
developed by two industry-leading companies -<br />
brick support specialist Ancon Building Products<br />
and Ibstock Kevington – national manufacturer of<br />
brickwork and masonry special shapes and<br />
prefabricated components.<br />
The new Nexus® system combines a specially<br />
developed Ibstock Kevington lightweight brick-faced<br />
steel unit with Ancon’s tried and tested MDC<br />
stainless steel bracket angle support system. The system offers contractors easier handling<br />
coupled with maximum adjustability, both vertically and horizontally, for quick and simple<br />
alignment on site.<br />
Working to a tight deadline, the<br />
specialist contractor’s experience and<br />
proven capability on complex projects<br />
was crucial. Furthermore, Prater’s inhouse<br />
design team made an invaluable<br />
contribution to the project overall, and<br />
the ability to utilise off-site fabrication<br />
at one of Prater’s factories helped to<br />
overcome significant logistical<br />
challenges on-site.<br />
Prater was appointed by main<br />
contractor Wates in a contract worth<br />
£2.5m to deliver the roofing and<br />
cladding package for Home. Overall,<br />
Prater was responsible for installing<br />
over 51 units of Reynaers Curtain-<br />
Walling, a range of Reynaers CS68<br />
Doors and Hortons 2001 Sliding Door<br />
units, as well as 826 Trimo Rainscreen<br />
Composite Panels and Radmat’s<br />
Permaquik hot melt waterproofing<br />
system for the roofing works.<br />
www.prater.co.uk<br />
The new system offers considerable benefits over traditional cast concrete alternatives –<br />
cutting weight by more than half, which in most cases will allow the brick-faced units to be<br />
installed without specialist lifting equipment, and significant savings in installation time –<br />
making it particularly appropriate for fast-track or time-limited projects.<br />
Rebrand transforms Roan to Actavo<br />
www.ancon.co.uk/Nexus<br />
Roan Building Solutions has been transformed into Actavo as part of Siteserv’s rebranding of<br />
all its companies including EventServ, Deborah Services and Sierra Support Services, to come<br />
together as one unified team.<br />
Operating globally in over 100 locations, the move to Actavo comes against the backdrop of a<br />
number of large-scale contract wins internationally. The change sees a transformation from<br />
being a holding company with autonomously operating entities in to one company with<br />
actively-managed, inter-related business solutions.<br />
Welcoming the rebrand, CEO of Actavo Structural Division, Roger Hastie, said: “Actavo will<br />
continue to deliver the quality goods, services and expertise we provided as EventServ, for<br />
example. In addition to this, we will be offering customers greater choice and a<strong>cc</strong>ess to the<br />
capabilities of the entire Actavo Group.”<br />
Commenting on the rebrand name, Vivienne Walshe, marketing director at Actavo, said: “The<br />
inspiration for the name Actavo comes from Actus, the Latin word for performance. Actavo<br />
reflects our dedication to performance, to energy and to our active spirit in pursuit of<br />
excellence. Furthermore, it is a call to action to our entire workforce of 4,500+ employees,<br />
incentivising everyone to find new ways to work better, reach higher, go further, prosper and<br />
enable our customers to grow.”<br />
www.actavo.com.<br />
46
Bu<br />
ilding Board<br />
Systems fro om your<br />
sol utions-fo cused<br />
con nstruction n partner<br />
SHEATHING<br />
FI<br />
RE<br />
ACOUSTICS<br />
Cement Particle Sheathing Board<br />
Class ‘0’ reaction to fire<br />
BS 476 part 22 Fire Te ested Systems<br />
CE marked a<strong>cc</strong>ording to EN 13986<br />
E N 594 Racking Test<br />
for<br />
Walls<br />
Cement Particle Sheathing Board<br />
Class ‘0’ reaction to fire<br />
BS 476 part 22 Fire Te ested Systems<br />
CE marked a<strong>cc</strong>ording to EN 13986<br />
E N 594 Racking Test<br />
F SC Chain of Custody Certificationtion<br />
fo or Walls<br />
RE ENDER BOARDS<br />
F ire and Acoustic Floor System<br />
Class ‘0’ reaction to fire<br />
E N 1195 tested<br />
fo or Floors<br />
PA<br />
ARTITIONS<br />
WALLS<br />
FLOORS<br />
ROOFS<br />
F ire and Acoustic Lining Board /<br />
Rainscreen Carrier<br />
A1 non-combustible reaction to fire to<br />
E N 13501-1 EN 12467<br />
Helps gain compliance with BR 135<br />
E N 594 Racking Te est<br />
fo or Walls<br />
F ire Protection Board<br />
A1 non-combustible reaction to fire to<br />
E N 13501-1 EN 12467 EN 1364-1 &<br />
E N 1365-1 tested systems<br />
fo or Partitions and Walls<br />
Direct Render Base Board<br />
Class ‘0’ reaction to fire EN 12467<br />
BBA certified systems<br />
Compatible with a wide range of<br />
le<br />
eading manufacturers’ base coats<br />
fo or Walls and Soffits<br />
Contact our technical/sales team for a quotation<br />
01925 860999<br />
www.euroform.co.uk<br />
info@euroform.co.uk<br />
FSC ® C084663<br />
This advert i s a general guide and specific technical advice<br />
is recommended before proceeding wi th any<br />
transaction. F ull technical information available on 01925 860999.