Innovation in Construction A Project Life Cycle Approach

5.3 Case study 2: The CastlefieldsEstate Regeneration ProjectTHE CONCEPTThe Castlefields Estate Regeneration Project inRuncorn, Cheshire is a unique 10 year partneringregeneration scheme that has delivered an awardwinning range of over 500 units of new housing, as partof the vision for a sustainable future for Castlefields. Thisproject is a successful example of collaborative partnershipbetween Plus Dane Group and Cruden Constructionthat embraced ‘Rethinking Construction’ principlesand achieved continuous improvement through theapplication of lean construction. The CastlefieldsRegeneration Partnership is using more than £44m offunding to completely revitalise this estate. The masterplan proposed a comprehensive programme of over 50individual projects from the redesign of infrastructureand transport to community facilities and modern mixedtenure housing. The next phase of regeneration includesthe redevelopment of the existing local centre, into anew community hub.INNOVATION JOURNEY/STORYInnovative ProcurementThe basis for all successful business processes employedthroughout the Castlefields regeneration started fromthe close relationship and integration of the projectteam. It was essential that all members of the team,including key supply chain partners, were included inplanning and programming as early as possible. Thispartnering approach enabled design to be rationalisedand input from Cruden Construction and the timberframe supplier taken into account in the early stages ofthe design process.Cruden and Plus Dane achieved to adopt innovativetechniques through applying lean principles and theyformed a partnership with Space 4 as the timber framesupplier and maintained this partnership for years. PlusDane Group employed RWD as consultants to aid in thedevelopment of methods and procedures to improve siteprocesses. Plus Dane determined to work with Crudento eliminate the initial cost barriers of modern methodsof construction (MMC) in order to reap long term savingsand benefits. The funding of RWD by Plus DaneGroup and the agreement to further invest jointly withCruden Construction demonstrates both partners’ desireand willingness to engage other specialists who couldhelp to drive out waste through the adoption of lean.These benefits have been brought through from phaseto phase, demonstrating continuous improvement.One of the most important ingredients of anysuccessful regeneration partneship is the involvement of the local community. Residents of the Castlefields estatehave been heavily involved in the regeneration processas well as in the development of each individual scheme.Project team members have had the opportunity toestablish positive working relationships with the localcommunity, and better understand the needs and wantsof the residents affected by the redevelopment.Innovative Modern methods of constructionTimber is renewable, sustainable, recyclable, non-toxic,waste-efficient and bio-degradable and as such thereis no other building material that matches its positiveenvironmental impact. Timber frame is a structuralsystem that has been tried and testedthroughout the world for centuries. It is the mostenvironmentally friendly form of construction available thatconforms to Modern Methods of Construction (MMC) andOff-Site Manufacturing (OSM) principles. A study carriedout by the Building Research Establishment (BRE) showsthat modern timber frame construction produces nearzero carbon emissions. Timber frame is renowned for itsexcellence in energy efficiency terms. Timber frameis engineered to the highest level of accuracy andquality; promotes greater efficiency and supply chainintegration; brings predictability and greater control tothe construction process; improves construction healthand safety; and has fewer defects and high customersatisfaction.There are many forms of timber frameconstruction to choose from, including advanced and closedpanel, volumetric and hybrid systems. ‘Space 4’ closedtimber frames were used as the structural elements of thesuperstructure in Castlefields. By using MMC methods,the closed timber framed panelled units went fromground floor slab to panels in place in just twelve weeks- half the time of a similar traditional build. Packagedas house types, the panels were zipped together onsite and finished in facing brickwork, with render andcedar boarding alongside aspects of double heightglazing. The benefits of MMC were evidenced in manyways; not only was the site accident free, it was dryer andcleaner for the labour force to work on. There were alsobenefits for local residents too, with reduced levels ofvehicle movements and noise.23