MMC 5541 48 Nov'15 cc

Offsite given wings 

Juliet Woodcock looks at a new 

concept surrounding modern 

methods of construction. 

MODERN METHODS OF CONSTRUCTION 

> issue 5541 | Nov | 2015 

‘Traditional’ approach to island 

PassivHaus properties 

MMC Magazine’s Bruce Meechan 

reports on a substantial low energy 

development by one of the southeast 

of England’s largest 

housing associations. 

Glazing systems specialist Kawneer expands its curtain wall portfolio > See page 12...

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CONTENTS 

issue 5541 | Nov | 2015 

Dear Reader, 

We often see parallels drawn between construction 

and the automotive industry, especially when it 

comes to mimicking the car-makers’ levels of 

efficiency and low waste through the adoption of 

“Modern Methods” -but a very uncomfortable 

analogy has emerged since our last edition. 

VW has been heavily criticized after US authorities 

exposed its use of ‘Defeat Software” to conceal the 

true levels of pollution emitted by millions of the 

company’s diesel vehicles, landing the company 

with massive compensation claims from 

purchasers who rightly feel duped, and slashing its 

stock market value. 

I often buy shares when a blue chip company takes 

such a hit, but this time I fear there is worse news 

to come, while it also makes me ponder the 

increasing amount of reports I am seeing about 

new properties drastically underperforming in 

terms of their energy usage. It seems in such areas 

as cold-bridging and preventing air leakage, our 

housebuilders are struggling to get things right in 

practice. 

We are a long way at present from seeing 

disgruntled home-buyers starting class actions in 

the courts, but some kind of fiscal punishment 

from Government is much easier to imagine. 

Almost certainly, increased use of offsite 

technologies will help close the performance gap 

between design and occupant consumption. 

Meanwhile, with 38 of Britain’s 43 air quality zones 

exceeding EU safety limits for nitrogen dioxide, and 

air pollution estimated to be responsible for 

28,000 deaths a year, perhaps we should be 

making more use of products such as the coating 

to roof tiles which digests NOx, and also try to 

develop new homes in localities that will minimize 

vehicle usage. 

Yours sincerely 

Bruce Meechan 

Editorial Enquiries Tel: 01827 301190 

Press Releases, Advertising, Production, 

Design & Circulation Enquiries 

Tel: 01827 301198 

Features Editor Bruce Meechan 

News Editor Juliet Woodcock 

Press Co-ordinator Gemma Spilsbury 

press@wavcoms.co.uk 

Advertising Kevin Edgeworth 

kedge@wavcoms.co.uk 

Design Ellie Rich and Di Smith 

Circulation 

circulation@wavcoms.co.uk 

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Tamworth, Staffordshire. B77 4AS. 

10 Offsite given wings 

Juliet Woodcock looks at a new concept 

surrounding modern methods of construction. 

12 New unitised curtain walling 

launched by Kawneer 

Glazing systems specialist Kawneer expands 

its curtain wall portfolio. 

32 ‘Traditional’ approach to island 


MMC Magazine’s Bruce Meechan reports on a 

substantial low energy development by one of 

the south-east of England’s largest housing 

associations. 

38 Shackerley’s engineered stone 

façades shape up beautifully 

Shackerley has demonstrated the 

extraordinary design potential and versatility 

of its Sureclad ® ventilated cladding offer by 

supplying an innovative engineered stone 

façade system for a challenging installation at 

Kew Bridge West. 

< Front cover 

18 STEICO – natural products for 

healthy buildings 

STEICO products are innovative building 

materials that offer long-term performance, 

increase the comfort of living and help to 

visibly increase the energy efficiency in 

buildings. 

32 Building fabric in the firing line 

Technical Editor Bruce Meechan reports from 

the Inmarsat Centre in London about a wide 

ranging conference staged there on November 

18th. 

Leading architectural aluminium systems supplier 

Kawneer has brought 50 years’ expertise to the 

launch of a new fast-track dry-glazed unitised or 

off-site curtain walling system that is an exemplar 

of Modern Methods of Construction. 

See page 12 for more info... 

www.kawneer.co.uk 

10 

MMC Nov 2015 3

NEWS 

Smart Cities, Big Data & 

the Built Environment 

The School of the Built Environment (in 

partnership with School of Real Estate 

and Planning) has recently won a 

prestigious grant from the RICS Research 

Trust in its special 'big data' call. The 

research (which is led by Professor Tim Dixon 

with Professor Martin Sexton and Dr Jorn 

Van de Wetering) will examine the drivers and 

barriers for big data platforms at city level in 

the UK. 

The smart city model provides huge 

opportunities to create added business and 

economic value from the integration of big 

data, covering many areas of the built 

environment. These include data relating to 

buildings, land use, planning, environmental 

data, health, economy, and energy. 

“More offsite” says 

build systems 

manufacturer 

The UK construction industry will benefit 

from increased opportunities for 

professionals to develop their 

knowledge of offsite construction, according to 

John Smith of Stewart Milne Timber Systems. 

Head of Technical, John Smith, believes that as 

more professionals are given the opportunity 

to understand offsite construction’s 

advantages and the latest developments which 

might assist them, the industry as a whole will 

benefit. 

To contribute to this, Stewart Milne Timber 

Systems offered a CPD session at its Witney 

facility in September, which was hosted in 

partnership with the Structural Timber 

Association (STA) and was free of charge to 

housebuilders, quantity surveyors, 

construction managers, directors, and 

affordable housing providers. It carries official 

CPD-accreditation for Royal Institute of British 

Architects (RIBA) members and included UK 

building industry “needs more offsite 

construction CPD” says the leading build 

systems manufacturer. 

John Smith said: “We believe that offsite 

construction has an important part to play in 

shaping the UK’s construction industry in 

coming years, and will continue offering CPD 

opportunities such as this in future. We expect 

to see similar offers from the rest of the 

industry as more professionals begin to 

employ offsite construction methods.” 

Researcher looking for ways to build a million new 

homes 

ALoughborough University researcher, engineer Ron Lang, hopes his study into house 

construction could revolutionize the way homes are built in the UK. His research is in the 

final stages of a four-year project looking at alternative methods of constructing 

housing. 

Whilst many researchers continue to look for ways to move the production of houses away from 

site and into factories, Ron believes there is a solid case for developing traditional methods. 

To identify alternative construction methods, six full-scale test walls with varying specifications 

have been constructed at Loughborough University’s School of Civil and Building Engineering. 

The walls were constructed under site conditions to allow Ron and his team to assess the build 

process for each alternative solution. 

He said: “If we can simplify on-site construction, we can improve the quality of our homes, speed 

up the home-building process and help the government to achieve its target of one million new 

homes in England by 2020.” 

The project is jointly funded by the Engineering and Physical Sciences Research Council (EPSRC) 

and Leicestershire-based company, Aggregate Industries (part of the LafargeHolcim group). 

Industry support has also been received from Gusto Construction, Tarmac Building Products, 

Forterra (formerly Hanson Building Products) and Low Therm Solutions. 

Builders bin the pub 

Forget the pub, white van men are more likely to be found in the gym working out than drinking 

pints, according to a new survey. 

A study of 1,000 tradespeople* by IronmongeryDirect, online and mail order supplier of ironmongery 

products to the trade, found that a substantial 69% of tradesmen don’t go to the pub that often, and 10% 

never go. 17% go once or twice a week but only 2% go most days and the same percentage every day. 

However, 32% claimed that they regularly go to the gym and exercise, and 50% said they are watching 

their weight. 13% are currently on the Atkins diet, 13% are using Slimming World, 11% use Herbalife, 8% 

are on the 5:2 diet and 5% are with Weight Watchers. 

The survey was conducted as part of IronmongeryDirect’s ‘The real white van man revealed’ campaign, 

which aims to shed the stereotypes often associated with tradespeople. 

Work starts on new accommodation for Army 

medics 

The Defence Infrastructure Organization (DIO) has started work on new en-suite single 

living accommodation for Army medics at Keogh Barracks in Ash Vale, Surrey. 

The £3.9 million project is being carried out in partnership with modular construction 

specialists, Rollalong, and is planned to complete in summer next year. 

Once finished, the 70-bed facility will conclude the modernization of junior ranks 

accommodation at the barracks. It follows recent works to convert existing accommodation 

from multi-occupancy rooms to single rooms. 

It’s part of a wider £50 million redevelopment project to enhance the barracks over four years 

for its new occupants. 

4 Armoured Medical Regiment (4AMR) relocated to the site earlier this year from nearby 

Normandy Barracks in Aldershot, while22 Field Hospital and Ministry of Defence Hospital Unit 

(Frimley Park) are scheduled to move to Keogh Barracks starting next year, following further 

refurbishment and new buildings. 

Over £30 million of remaining major works will follow with procurement starting shortly to 

provide a new Sergeants’ Mess, stores, vehicle workshops and an armoury. 

The redevelopment of Keogh Barracks is part of the Army Basing Programme (ABP), which is 

providing the facilities the Army needs to live, work and train in the UK as it returns from 

Germany, relocates bases across the UK and restructures under Army 2020. This year more 

than 5,000 Service personnel have returned to the UK from Germany and 1,800 have relocated 

within the UK as part of the programme. 

4

Addressing poor air 

quality 

Research shows that modern airtight 

homes are more likely to 

suffer from poor indoor air quality 

and leads to change in Scottish building 

regulations. 

After years of research into poor indoor air 

quality in modern homes, a team of British 

architects have been recognized by the 

Chartered Institute of Building Services 

Engineers. Dr Stirling Howieson, University 

of Strathclyde, Dr Tim Sharpe, Mackintosh 

Environmental Architecture Research Unit 

and Paul Farren, ASSIST Design Ltd. were 

presented with the Napier Shaw Bronze 

Medal award on 9th October 2015 at the 

annual CIBSE President’s Award Dinner for 

their 2014 research paper, “Build Tight, 

Ventilating Right?” which demonstrated 

that standard air tightness levels within 

houses constructed to current regulations 

are likely to result in poor indoor air 

quality. 

Further research by the team, undertaken 

on behalf of the Scottish government, has 

led to a change in the Building Standards. 

From October 2015 all new homes in 

Scotland are to be fitted with bedroom 

CO2 monitors. 

Finalists announced 

for 2015 Offsite 

Construction Awards 

The inaugural Offsite Awards has seen 

fierce competition with a flood of 

high-calibre entries competing to be 

crowned as industry leaders of the offsite 

construction market. 

With nearly 150 entries across 12 

categories, the awards have been packed 

full of outstanding, ground breaking 

projects, products and people. The winners 

will be announced at a relaxed drinks and 

nibbles reception, to be staged at the 

Inmarsat Conference Centre in London on 

December first. 

The awards ceremony will attract over 300 

national business leaders and high profile 

decision makers from the offsite 

construction industry, plus architects, 

engineers, contractors and clients, 

providing a significant platform for 

targeting the offsite industry. The event will 

also present the ideal opportunity for 

professionals to maximize industry 

exposure and penetrate this innovative 

market. 

Each of the judges has assessed four of the 

12 categories on a strict and confidential 

marking system to establish the award 

category winners, highly commended and 

shortlisted entries. 

Offsite construction sector raising the bar on 

skills 

Employers in the offsite construction sector have signaled the importance of 

working together to recognize and address skills gaps if they are to capitalize on 

the growth opportunities available to the sector. 

The employers, including Skanska and Laing O’Rourke, have led five skills projects cofunded 

by the UK Commission for Employment and Skills’ (UKCES) Futures Programme. 

The projects piloted different approaches to improve sector collaboration and provide 

better training opportunities for both new and existing workers. 

In October, UKCES published findings based on the delivery of these projects which 

demonstrate: 

• The clear need for industry leadership to capitalize on the opportunities afforded by the 

industrialization of the sector. 

• Employers can raise the bar on skills in sectors, regions and supply chains, by working 

with each other, their employees, universities and professional associations. 

• Collaboration has been shown to be vital to building the skills needed for growth and the 

topic of skills has brought competing businesses together to address their common 

need. 

• Competitors can become collaborators where there is a commonly experienced 

challenge which can be better tackled together, and where there is a foundation of 

strong individual or group relationships which can be built upon. 

• The breadth and depth of skill gaps were sometimes greater than project teams first 

realized, but in recognizing the gaps, corrective action could be taken. The report shows 

that it is crucial for employers in the sector to take responsibility and recognize these 

gaps otherwise they risk being left behind. 

• Educators and businesses must work more closely together to ensure educational 

institutions and professionals keep up with technological advancements and ensure 

innovation can be capitalized upon. 

Revolutionizing green building technology 

Smartphones, thermal imaging technology anad cloud computing could boost Europe’s 

ability to meet energy efficiency goals 

A €6.4 million project to revolutionize the way our industry delivers green buildings was 

launched in London on the 17th November. 20 UK and European partners will create new 

smart tools and cloud computing platforms to transform the energy efficiency and 

construction industries. Funded by our contributions to the Horizon 2020 programme – an 

€80 billion research and innovation fund – the ‘Built to Specifications’ (Built2Spec) project will 

use new technology to radically improve the design, installation and testing of building 

standards and retrofit. Together, the measures will help the built environment hit 2050 

carbon targets and reduce fuel poverty. 

CPA’s Skills Report ways to formalize 

construction training 

Manufacturers and distributors of construction products run thousands of training 

programmes for the builders and tradespeople who install their products. An 

opportunity exists to put that training on a formal footing with nationally recognized 

qualifications, according to a report from the Construction Products Association. 

‘Skills Report 2015’ – produced with support from the Construction Industry Training Board 

(CITB) – is the third in a series of projects that the CPA is contributing to understand skills and 

materials constraints facing the industry. It maps the large number of training activities which 

association members currently run, particularly for ‘product-users’, and recommends a new 

process to align that training to recognized qualifications. 

MMC Nov 2015 5

Product News > 

Setcrete puts in a 

High Performance 

Setcrete’s new High Performance floor 

levelling compound was found to be 

the perfect product for a problematic 

flooring installation at a home in 

Wythall, near Birmingham. By using 

Setcrete’s specialist, fibre-reinforced 

High Performance product, contractors 

were able to apply the levelling 

compound over both a plywood and a 

sand/cement screed subfloor in a 

single application - completing a 

perfect flooring installation, with a 

smooth, professional finish, in a matter 

of hours. And the rapid-setting 

properties of Setcrete High 

Performance meant that the newly 

levelled subfloor was ready to receive 

new floor-coverings in just four hours. 

UK first for Portaloo 

There are more than 230,000 people with disabilities in the UK who need more support and 

specialist facilities than standard accessible toilets provide. In response, Portaloo, part of the 

Portakabin Group, has launched Portaloo Accessible Plus – the UK’s first self-contained, semipermanent 

toilet and shower building for wheelchair users and their carers which is available 

for short or longer-term hire. 

The building has a series of unique features including an integral, wheelchair-accessible 

shower for ease of washing, a weight-bearing ceiling track hoist for the safe transfer of users 

from a wheelchair to the WC, shower or changing bench, and a height-adjustable wash basin. 

Cembrit get a high five from the BBA 

Cembrit has the distinction of having its 

complete range fully accredited by the BBA 

(British Board of Agrément), holding five BBA 

Certificates for its fibre cement slate range. 

The Cembrit range of fibre cement slates 

includes Westerland, Moorland, Zeeland, Jutland 

and Diamond, all offering their own unique 

appearance. The slates are ideal for use on 

conventional pitched timber roofs with a rafter 

pitch of 20° and over, or hung vertically as 

cladding on external walls. The slates are 

complemented by matching fibre cement ridges, 

ventilation solutions, and fixings. 

All Portaloo Accessible buildings are delivered fully 

plumbed in and fitted out, ready for immediate 

connection to water, waste and energy services. 

Portaloo will also provide foundations, Equality Actcompliant 

access ramps, and fast installation for the 

shortest possible procurement periods. 

www.portaloo.co.uk/accessible-plus. 

Manufactured to the highest European standards using Portland cement together with a 

formulation of superior blended synthetic and cellulose fibres, Cembrit fibre cement slates are 

finished with a high quality, semi-matt acrylic coloured coating to the face and edges and a 

tinted, high performance binder to the back face. Cembrit fibre cement slates are the most 

accredited on the UK market. 

www.cembrit.co.uk 

Zehnder launches new website 

The ‘flexible’ properties of Setcrete 

High Performance make it suitable for 

use over a wide range of subfloor 

types, including sand/cement screeds 

and, crucially, plywood. After overboarding 

the wooden subfloor with 

flooring grade plywood and applying 

Setcrete Acrylic Primer, contractors 

were able to apply High Performance 

onto the entire refurbishment area, 

including over both wooden and 

concrete subfloors, in a single 

application. 

www.setcrete.co.uk 

European indoor climate specialists Zehnder have relaunched 

their UK website, Zehnder.co.uk. Delivering an 

enhanced user-friendly experience with improved navigation 

and functionality throughout, it allows customers to access 

detailed product information and videos across multiple 

platforms. After registering for a my.Zehnder account users 

can also take advantage of a more personalised experience 

with the ability to save any brochures, planning 

documentation or data sheets to their own account, for 

immediate access in the future. 

“Our full range of BIM components are available for 

download, and application case studies provide a detailed 

overview of Zehnder’s capabilities across a wide range of sectors, including manufacturing, 

offices, schools and hospitals,” explained Zehnder Brand Manager, David Simoes. 

In addition to a richer online content, better presentation and the incorporation of video, the 

website’s powerful radiator filtering and product selector tools enable installers and specifiers 

to more easily find the most suitable products for their projects. 

www.zehnder.co.uk 

6


Cembrit to invest in 

natural slate 

Cembrit has announced the creation of 

a dedicated natural slates division to 

offer the UK’s specifiers and slaters 

greater choice of top end material for 

prestigious roofing contracts. The 

philosophy will be to enhance the 

existing range with additional high 

quality slates. The new brands will 

offer reliable, long term availability. 

This will be supported by dedicated 

personnel and focused marketing. 

Prater to continue involvement in London Bridge 

redevelopment 

Since November 2013, specialist contractor Prater has been on site at the redevelopment of 

the iconic London Bridge station carrying out the design, supply and installation of everything 

from the track-bed up. This includes the fabrication and installation of the pre-cast concrete 

platforms, as well as roof canopies with associated high level glazing. Lead contractor Costain 

has further appointed them to install a glazing package across the platform level, street level 

and retail areas of the site. 

Prater will design, engineer and install a bespoke structural glazing system, to meet the 

specification of the redevelopment, with the 

platform and street level system being installed 

along the St Thomas Street façade. In a later phase 

of the project, a 260m2 SU72 shopfront glazing 

screen will be added to the retail area. 

The 10-week programme on the St Thomas façade 

is due to commence in late 2015, with the six-week 

SU72 installation currently scheduled for Summer 

2017. 

www.prater.co.uk 

Loading up! Metsec takes student living to the next 

level 

Light gauge structural steel specialist voestalpine 

Metsec plc has supported the renovation of Portland 

House, Exeter, a 1960s concrete framed building - 

part of a £17m luxury student accommodation 

scheme for developer Select Property Group, under 

its Vita Student brand. Originally a four-storey 

structure, Portland House has been converted into 

seven-storey student accommodation, totalling 161 

high-end flats with the use of Metsec’s load bearing 

steel frame structure (SFS) system. 

Metsec’s load bearing SFS system enabled three additional storeys to be added to the original 

concrete building without impacting the structure, due to its lightweight design. These 

structures are stick built on site, which ensures maximum flexibility of the structure, and there 

was no need for the use of cranes to build the SFS. With land expensive and scarce in city 

centres, building upwards on existing structures is key to solving the shortage issue, and SFS 

has proved to be the most cost- and resource-effective way to do this. 

www.metsec.com 

As a start of the investment and long 

term commitment to Natural Slate, the 

group has decided to dedicate a 

specific person to this product group, 

Sales Director, Rob Wallace. Rob has 18 

years of experience in growing 

Cembrit’s business from its Welsh 

depot in Llandow, achieved through 

unbeatable customer service. 

“This marks the beginning of a new 

phase in Cembrit’s commitment to 

natural slate,” said Marketing Manager 

Ged Ferris. “Cembrit will be making 

substantial investments in this 

environmentally attractive material. 

Look out for more news as the division 

takes shape.” 


David Wilson homes 

uses Vortice leto fan for 

prestigious new 

development 

A prestigious new development called Grey 

Towers Village in Nunthorpe near 

Middlesbrough will feature Vortice’s Leto 

fans in its three, four and five bedroom 

houses. The Vort Leto is an energy efficient centralised mechanical extract unit suitable for 

kitchen plus three wet rooms and is SAP Appendix Q listed. 

Roy Brown, Vortice Area Business Manager said: “Quite apart from its energy efficiency, the 

customer was particularly pleased with the quiet running of the Leto and the fact that it only 

required one breakout from the building.” 

Grey Towers village by David Wilson Homes combines the best of village life with the 

conveniences of modern living. It is built with a traditional village feel about it, including 

features like a beautiful pond, woodland and nature trails; the houses are spacious and 

incorporate energy efficient build methods. 

www.vortice.ltd.uk 

8

Offsite given wings 

Juliet Woodcock looks at a new concept surrounding modern methods of construction 

It has long been accepted that 

manufacturing construction elements in 

the factory environment is safer, ensures 

higher quality end products with reduced 

wastage and can help meet tight deadlines, as 

well as getting around the problem of the 

skills shortage we are still experiencing postrecession. 

But, as with every good idea, there is always 

someone who will take it one step further: on a 

large building contract, why not take the 

factory to the site? Indeed, a project funded 

through the Technology Strategy Board’s Low 

Impact Buildings Innovation Platform has 

undertaken a fundamental rethink of building 

processes, developing ‘flying factories.’ 

Led by Skanska, the project involves partners 

from ModCell, Exelin *the South West 

Manufacturing Advisory Service), the University 

of Reading, and the Building Research 

Establishment. Together they have developed 

the system of ‘near-site’ manufacture using 

modern flying factories. 

To develop the technique and secure funding, 

Skanska’s innovation team put together a 

research consortium of external organizations. 

Inspiration was taken from the offsite 

fabrication of May Park School in Bristol. 

Combined with virtual-reality-enabled supply 

chain management and process improvement, 

the system can provide a 28 per cent reduction 

in cost per square metre and 30 per cent 

shorter programmes, delivering higher quality 

and a more predictable build. 

“With flying factories you are 

not tied into big overheads or 

high transport costs; and you 

are adapting the factory to 

exactly fit your needs at the 

time, so the concept is opening 

up the potential for a massive 

increase in the level of offsite 

fabrication across the country” 

Sam Stacey, 

Head of Innovation at Skanska 

The concept was used to assemble wall panels 

for Glenfrome School in Bristol, enabling a 

building extension to be completed in just six 

weeks during the summer holiday. 

It was then successfully applied to the SRW 

engineering services project for the Battersea 

Power Station Development Company phase 

one, where 550 ‘utility cupboards’ have been 

created for residential use. Significant cost and 

programme savings have been recorded for 

both projects; for the Battersea scheme, cost 

and time savings of 44 and 65 per cent were 

achieved. 

If the Government is to reach its 2025 

construction targets of 33 per cent reduction in 

building costs and 50 per cent faster delivery, 

plus 50 per cent lower emissions, then near site 

factories could offer a significant part of the 

solution. 

Manufacturing components offsite, but close to 

the location for erection or installation helps to 

deliver many efficiencies: 

• Faster onsite installation 

• Minimal quality defects and associated waste 

• Optimized transport solutions to reduce costs 

• Overall reduction in operational and embodied 

carbon 

• Safer working environments for personnel 

• More likely to meet programme deliverables 

and reduce commercial risk 

• Avoiding the problems of poor weather 

10

Speaking exclusively to MMC Magazine, Sam 

Stacey, Head of Innovation for Skanska 

commented: “The concept of flying factories is 

that they are temporary and flexible so ideally 

they need to be located within 25 miles of the 

site where buildings will be located: so we will 

be looking at rented warehouse space or 

possibly temporary hire structures erected on 

hard-standing. Good transport connections with 

the final site are essential. 

Skanska has fabricated these large utility cupboards for an apartment project in Battersea, 

pre-fitted with all the M&E equipment including MVHR 

“It will also mean taking on labour on a 

temporary basis which, although it has not 

proved a problem to date, does require us to 

get people up to speed quickly in order to 

maximize the benefits. The approach then is to 

simplify the processes as far as possible, 

possibly taking steps out of the assembly 

process; and as much as possible making it like 

assembling a piece of furniture. 

“At present the design supply chain is not well 

established to facilitate this type of working, 

but we will look to use templates where we can. 

The advent of Building Information Modelling 

(BIM) also offers a good basis for progress and I 

believe we can benefit with 3-D modelling, as 

well as what we term ‘virtual rehearsals’. There 

is a degree to which we will have to be 

responsive to each type of assembly we have to 

work with. ” 

Apparently Sam Stacey’s team includes 

software specialists adept at working with 

virtual reality and they have already been 

experimenting with the Oculus type gaming 

headsets: making it possible to walk through 

some of the building prototypes currently being 

planned. This type of advancement could soon 

put the technology underpinning flying 

factories on an even footing with the 

automotive and other high tech industries. 

“I think this type of technology will be 

enormously helpful for those involved,” 

continued Sam Stacey, “To experience what we 

are proposing to build, including the 

construction sequence, and identifying any 

gaps in the design, or something we can 

improve in the process. It will be applicable to 

anything that can be produced as a pod: 

kitchens, bathrooms or the utility cupboards we 

have been producing for a residential 

development in Battersea – packed with the 

M&E equipment. 

“With flying factories you are not tied into big 

overheads or high transport costs; and you are 

adapting the factory to exactly fit your needs at 

the time, so the concept is opening up the 

potential for a massive increase in the level of 

offsite fabrication across the country. 

“ It is also a good environment to ‘tag and 

track’ all the components with RFID (Radio 

Frequency IDentity) tags which then facilitate 

quality checks and carry out condition 

monitoring to support condition based 

maintenance of moving and rotating 

machinery; particularly pumps.” 

Gary Peters from Exelin, reviewing the 

field tools for the tag and track solution 

Back in July, Skanska was additionally awarded 

£700,000 to develop construction robots, to be 

used to carry out several tasks, including 

cutting, drilling and fixing on site. The funding 

was awarded by Innovate UK and the 

Engineering and Physical Sciences Research 

Council (EPSRC) as part of their collaborative 

R&D programme; and it is expected that these 

robots will also be used in flying factories to 

further speed up the build process. 

Iain Gray, Chief Executive of the Technology 

Strategy Board, said of the flying factory 

notion: “The work we are funding will 

encourage the UK construction industry to 

undertake a fundamental rethink of current 

ways of working and enable businesses to 

explore potential commercial opportunities 

created by novel design, procurement and 

construction processes.” 

While capital investments are greatly reduced 

by rented space for flying factories, the pilots 

did reveal that the break in continuity of 

production could be an issue; which automation 

might overcome. Other lessons learned were 

that there needs to be an increased control 

over the start-up phase regarding decision 

making, early decisions and involvement of 

expertise, as well as increased control over the 

design and production process. 

MMC November 2015 11

New unitised curtain walling 

launched by Kawneer 

Glazing systems specialist Kawneer expands its curtain wall portfolio. 

Today’s safety-conscious and fast-paced 

construction schedules demand high 

performance, fast installation, simplified 

fabrication, superior performance and design 

flexibility. 

The DTI document “Manufacturing for the 

future” has long pressured the industry to 

increase awareness of off-site construction and 

build on the knowledge available across Europe 

and America. 

It clearly highlights that off-site construction 

should be considered for hotels, hospitals, 

schools and supermarkets. But in reality, 

because systems such as unitised curtain walling 

do not require scaffolding, they are suitable for 

any site where access is difficult or restricted - in 

itself a growing phenomenon, with 70% of newbuild 

now on brownfield sites. 

With curtain walling being one of the most eyecatching 

elements of a façade, its evolution from 

the traditional stick system to a unitised one is 

perhaps one of the most obvious signs that the 

Government’s drive off-site is being embraced. 

The factory production of unitised curtain 

walling from leading UK architectural aluminium 

systems supplier Kawneer gives predictability of 

time and cost, guarantees quality that reduces 

problems, delays and snagging on site, and 

avoids delays caused by adverse weather 

conditions. 

On-site time can also be reduced substantially, 

saving labour costs and minimising local effects 

such as noise, dust and traffic congestion. Where 

there is a shortage of skilled site labour, off-site 

manufacture ensures high build quality is 

maintained. 

Now Kawneer, which has 50 years of unitised 

curtain walling expertise, has enhanced its 

extensive curtain wall portfolio with the launch 

of a new fast-track dry-glazed unitised system. 

The AA ® 265 incorporates a three-chamber 

system and overlapping gasket design for 

optimum weather tightness. Its dry-glazed 

assembly combined with the use of the same 

extrusion to all four sides provides both ease of 

fabrication and the opportunity for effective bar 

optimisation. 

In addition, if access during installation is 

limited, the AA ® 265 system can be installed 

under restrictive working conditions, with the 

building remaining occupied. 

The optimum weathering is achieved by zonedrained 

pressure equalisation, with the glazing 

providing a positive weather seal for high 

performance. The system also features an 

exclusive high-performance thermal break. 

Its slim 65mm sightlines, picture-frame style 

capping, integral vent option and dual-finish 

gives specifiers a wide choice of options to 

create individual and exciting building facades as 

the AA ® 265 can accommodate spandrel infill 

panels of glass, stone and metal up to 50mm. 

Adaptable to any new construction project from 

two storeys upwards, the AA ® 265 system has 

been exclusively designed and developed by 

Kawneer, with installation contracts undertaken 

in collaboration with its network of authorised 

dealers. 

Kawneer’s unitised range of curtain walling also 

includes the AA ® 201 unitised system which 

suites with the company’s AA ® 130 Brise Soleil, 

has 63.5mm sightlines and can accommodate 

infill panels up to 32mm. 

As well as many of the features of its sister 

AA ® 265 system, the AA ® 201 is available with 

fully-capped and SSG (Structurally Silicone 

Glazed) options in addition to a horizontal cap 

with vertical silicone joint, vertical cap with 

horizontal silicone joint and a range of mullion, 

transoms and face cap options with 63.5mm 

Photo: David Cation 

St Andrew House, 

Glasgow 

AA ® 265 

Unitised 

Curtain Wall 

sightlines. Both the AA ® 265 and AA ® 201 

systems have been tested and certified to the 

stringent CWCT (Centre for Window and 

Cladding Technology) Curtain Wall testing 

standards. 

A more detailed guide to the benefits of unitised 

curtain walling for off-site construction are 

contained within Kawneer’s RIBA-approved CPD 

which advises architects and specifiers about 

the manufacturing process and testing regimes 

for such systems, how they are different to 

traditional “stick” curtain walling and how they 

are installed. 

Kawneer is also able to offer a range of stick 

curtain walling systems including the AA ® 100 

and AA ® 110 systems with 50mm and 65mm 

sightlines respectively. The AA ® 100 system is 

also available in a fire-rated version. 

Tel: 01928 502604 

www.kawneer.co.uk 

Click on the QR Code to view 

our 3D Interactive Model 

12

Revolutionis 

e 

your 

project 

delivery 

Skanska Fabrications can improve quality, minimise 

cost and reduce installation time on your project by 

manufacturing mechanical, electrical and plumbing 

system elements off-site. 

Our projects include commercial buildings such as 

30 St Mary Axe (the Gherkin), high quality residential 

apartments, schools and healthcare facilities, 

plus many more. 

To find out how you could save time and money, 

while improving on-site safety, contact us on 

01753 554215 or srw.enquiries@skanska.co.uk. 

www.skanska.co.uk

Article > 

Timber frame construction & the 

risk of disproportionate collapse 

A £1.4 million five-storey development of some 1,700 square metres, accommodating 23 individual apartments, 

Aubrey Street in Herefordshire was a substantial project for timber frame specialists Taylor Lane. 

Versaliner liner Sheets 

Taylor Lane had been engaged by the 

main contractor Speller Metcalfe, an 

award-winning sustainable construction 

company, with expertise in BREEAM, 

Passivehaus and the Code for Sustainable 

Homes. 

The Project 

The development, for client Matches Housing 

Association, was to be constructed in close 

proximity to several existing properties on 

three sides. As is often the case with 

developments where space and access are 

restricted, off-site construction methods 

present an attractive solution. Taylor Lane 

specialise in manufacturing structural grade 

C16 timber frame panels in a quality-controlled 

factory environment. 

Prior to Aubrey Street, Taylor Lane’s timber 

frame panels incorporated an external 

sheathing layer comprising, typically, either 

OSB or plywood, depending on the application. 

Indeed, the specification for Aubrey Street had 

specified just these kinds of materials. Taylor 

Lane decided that something more was needed. 

The Challenge 

The close proximity of the site to other 

buildings and the risk of disproportionate 

collapse meant that the consequences of 

14 

accidental fire or even a possible arson attack 

had to be taken very seriously. This is a 

particular hazard faced by timber frame 

construction projects. In fact, the Structural 

Timber Association has launched several 

initiatives to combat this phenomenon, 

including detailed guidance. 

According to the STA guidance, “All buildings 

should have appropriate fire protection 

designed and built-in as early as possible and 

maintained throughout the entire construction 

phase… For small or low-risk sites, the general 

good housekeeping and standard approach 

may be more appropriate… For other sites the 

sub-division of the frame by fire-resisting 

barriers must be considered as part of the 

strategy for minimising fire spread risk during 

construction. 

The solution 

Aubrey Street certainly didn’t fall into the 

“small or low-risk” category. Consequently, 

Taylor Lane opted to use Euroform’s Versaliner 

instead of the specified OSB. 

Versaliner is an A1 non-combustible Magnesium 

Oxide sheathing board with excellent tensile, 

compression and breaking strengths, and high 

resistance to impact, moisture and insect 

attack. Excellent racking resistance means it is 

particularly suited to timber frame applications, 

offering additional stability. The fact that 

Versaliner is a “score and snap” materials 

means it can be fabricated on-site without the 

need for additional cutting equipment or can be 

seamlessly incorporated into the streamlined 

processes of off-site, factory-based 

construction. 

Taylor Lane worked closely with Euroform’s 

technical team, taking advantage of their 

expertise and experience in the complex area 

of passive fire protection, to ensure Versaliner 

was the appropriate product for this particular 

application. 

Duly satisfied that all their criteria had been 

met and all their concerns addressed, Taylor 

Lane began incorporating Versaliner into their 

timber frame panels as part of their off-site 

construction process. 

A spokesperson for Taylor Lane said, 

“Versaliner enabled us to safely build on a site 

where fire risk was a significant factor. Without 

it, we’d have struggled to proceed. We’re more 

than happy with the product, it’s very 

competitive pricing and ready availability.” 

www.euroform.co.uk

Can rooftop extensions be a solution to the housing crisis? 

The shortage of suitable land for housing, particularly in London, 

is recognised as one of the reasons why we are continually 

hearing about this nation’s housing crisis. During the 19th 

Century land was also at a premium and the advancement of 

engineering developments, including the first passenger lifts, made it 

possible to build habitable high rise accommodation. This method of 

building continued to grow in popularity with many UK cities seeing a 

large number of high rise blocks erupting from the 1930s-1970s. Many 

of these buildings were over-engineered to such an extent that it is still 

possible for the structure and foundations to support up to 50% more 

floors than originally constructed. With the advances in engineering 

technologies in MMC this spare structural capacity can be exploited to 

provide a solution to housing needs without the need to use more land. 

Social issues and transport links aside, the first step in determining if a 

particular scheme is suitable is to identify which buildings are likely to 

gain planning approval and have the necessary structural engineering. 

If the structural report confirms there is sufficient integrity within the 

structure the next step is to identify which system is most appropriate 

for the intended purpose. Modular light gauge steel offers significant 

benefits and will fit many common situations. 

The solution on offer from Premier Modular Limited provides a cost 

effective, high quality system which will be constructed in an ISO9001 

and ISO14001 factory environment. The volumetric rooftop extension is 

then transported to site and installed with significantly reduced time on 

site and minimal disruption for existing residents. The Premier Modular 

system allows the roof to be factory fitted with the option of a vaulted 

ceiling. The end result is a high quality living accommodation built to 

all relevant standards including Life Time Homes which can be 

mortgaged, complete with a 10 year insurance backed warranty through 

Checkmate. 

To find out how we can help you with your rooftop extension project, 

please contact us on 0800 316 0888 or 

graeme.odoherty@premiermodular.co.uk or 07824 303843 


Modular Volumetric > 

Portakabin Group wins 

Environmental Business of the 

Year award 

The Portakabin Group’s commitment to sustainability has been 

recognised with another award, having been named Environmental 

Business of the Year in the Yorkshire Post Environment Awards 

2015. The award was presented 

at an event in Leeds which 

celebrated the achievements 

of organisations working to 

combat global warming and 

create truly sustainable 

communities. This follows the 

Group’s success in a number of 

national awards for recycling 

and zero waste. 

Portakabin Group was 

honoured for its environmental 

commitments which cover 

every aspect of its business – 

from its achievement of 

generating zero waste to 

landfill in the manufacture of its market-leading modular buildings, 

to its sustainable transport initiatives which encourage cycling, car 

sharing and the use of public transport to reduce carbon emissions. 

www.portakabin-group.co.uk 

Portakabin Group awarded UK’s 

largest ever education sector offsite 

contract 

The London Borough of 

Barking and Dagenham 

has been awarded what 

is believed to be the 

largest ever off-site 

contract in the 

education sector, to the 

Portakabin Group – a 

£44m project to deliver 

an innovative threeschool 

campus. 

The 23,000m2 Riverside Schools scheme is one of the largest 

school projects now under construction and will provide additional 

places for one of the fastest-growing school-age populations in the 

UK. The campus will have capacity for around 2,700 children from 

0-19, integrating provision for nursery, primary, special needs, 

secondary, and sixth form. 

The Portakabin Group is main contractor for this pioneering 

project, and will use a Yorkon off-site solution for the curriculum 

areas. The use of off-site construction will significantly reduce the 

programme time; the project has been scheduled to complete the 

primary and SEN facilities in time for the start of the 2016/17 

academic year. 

www.yorkon.info 

Build with Confidence 

Magnesium Oxide Board Corporation enters the UK construction industry with the opening of new offices and warehousing facilities in 

Harlow Essex. 

MgO Corp has established a strong global foundation over the past 7years based on attention to detail and performance of our products, 

strong industry hands on knowledge and the highest professionalism aptitude in the building industry regarding mgo based composite 

products. 

Peace of Mind with The World’s Highest Level of Compliance 

ResCom ® building products and our manufacturing facilities are thoroughly audited by independent third party inspectors to assure the 

highest compliance for use in building and construction under multiple global building codes including but not limited to: 

United Kingdom: BS EN Standards 2015 - Australia: BCA Standards 2015 - New Zealand: NZBC Standards 2015 - Sweden: SWEDAC Standards 

2015 - Malaysian Standards Authority 2014 - Guatemala: FHA Standards 2015 - USA: ASTM - NAMI 2015. 

Lifetime Benefits 

MgO Corps ResCom ® building products greatly benefit us in all aspects of life by immediately 

decreasing global greenhouse gasses, lowering carbon footprint of developments and offering 

our families safer, stronger, healthier and more sustainable protection from the elements of 

water, wind, fire and the cold. 

ResCom ® Building Products are a direct replacement for traditional gypsum / plasterboard and 

FC linings. ResCom ® delivers revolutionary composite materials that are above FRL60 and 

reduce the use of fire rated wall lining from 67% to 50% without any reduction in 

performance (tested and proven). For further detailed information or to arrange a meeting 

contact: 01279442831 or email info@mgoboard.co.uk 

Mgo will stock their full range of board products from 4mm boards up to 25mm in lengths and 

widths of 1200 to 3000 and also their 18mm-22mm flooring products. 

Mgo will supply their quality Residential and Commercial ResCom ® boards to Builder’s 

Merchants Modular House Manufacturers, Construction Companies and other end users in the 

UK. 

wwwmgoboard.co.uk 

16

Ecological Insulation made from renewable resources 

Healthy Buildings and Lower Energy Costs 

Natural Insulation 

Natural Insulation Boards 

Flexible wood fibre suitable for 

roof, floor and timber frame wall 

applications. Excellent all round 

insulation properties improves the 

fabric and makes buildings a better 

place to live and work in whatever 

the weather. 

Wood fibre building boards for 

sarking, sheathing, acoustic and 

render applications. Diffusion 

qualities provide healthy living 

with protection against wind, dust, 

moisture and sound. 

For full details and nearest distributor 

call 01727 515120 or visit www.steico.co.uk 

10-34-76 

ENGINEERED 

BY NATURE

Article > 

STEICO – natural products for 

healthy buildings 

STEICO products are innovative building materials that offer long-term performance, increase the comfort of living 

and help to visibly increase the energy efficiency in buildings. STEICO products are especially economical and 

environmentally-friendly as they are produced from sustainable resources. 

STEICO Joist in roof application 

STEICO Special and STEICO 

Flex in a roof refurbishment 

< STEICO Joist close up 

Whether for engineered timber 

elements or insulation materials, 

roofing boards or wall panels, 

STEICO offers a suitable product for each 

building application. In the UK market STEICO 

is best known for its market leading I Joist 

which many of the major builders use in their 

developments. Increasingly smaller builders 

and developers are also changing from solid 

timber to I joists due to the performance, light 

weight and ease of access for service runs. 

Complementing STEICO joists a brand new 

state of the art 80,000 cbm Laminated Veneer 

Lumber plant has recently been commissioned 

and started production in September 2015. This 

makes STEICO unique in that it is the only 

European company to manufacture all the 

components of the I Joist. This gives 

distributors and end users a guaranteed robust 

supply channel with maximum control of costs 

going forward. 

STEICO is also the UK market leader in thin 

wood fibre underlay boards for use under 

laminate and wood flooring systems and is the 

product of choice for many professional floor 

fixers. Many of the own branded wood fibre 

underlay products in the major DIY chains are 

manufactured by STEICO. Other products 

showing significant growth in the UK are 

18 

boards for sarking applications, a partnership 

with Lime Green Products using Protect 

breathable render carrying board, and Flexible 

wood fibre batts in timber frame new build, 

refurbishment and commercial projects. 

All the insulation products benefit from the 

inherent properties of the natural materials 

that they are made from. The natural fibre 

insulation materials, for example, are 

distinctive as they offer diffusion qualities that 

contribute to a healthy indoor climate. The 

joists, used as construction elements, also 

follow nature’s examples and combine lean 

design and lightweight properties with a high 

load capacity. All products are easy to handle, 

non-allergenic and durable, real future proof 

building materials. 

Warm in winter – Cool in summer 

Worldwide more energy is used for cooling 

buildings than for heating them. Based on this 

it is reasonable to appraise the efficiency of an 

insulation product not only for its ability to 

prevent energy loss in winter months but also 

for its protection from heat ingress during the 

summer months. STEICO products provide a 

low thermal conductivity combined with a high 

heat storage capacity. Due to these special 

factors a comfortable cool environment in 

summer and a comfortable warm environment 

in winter can be achieved. 

Pro Environment – Pro Living 

While choosing materials and production 

methods, STEICO, as a producer of wood based 

ecological building materials, pays particular 

attention to the environment and healthy living. 

There is a clear commitment to meeting the 

needs of the present without compromising the 

needs of future generations with products that 

perform in both function and quality. The entire 

range of STEICO Insulation products are 

certified by FSC®, ensuring sustainable 

traceability of the raw wood fibre materials. In 

addition, the insulation boards also carry the 

seal of approval from the Passivhaus Institute 

and the Institute for Building Biology (IBR), 

Rosenheim, both of whom acknowledge the 

high energy efficiency performance gained by 

using STEICO products in many building 

applications. 

STEICO has its own sales and marketing office 

in the UK and its experienced staff offers 

technical advice on product use to supply chain 

partners, house builders, developers and 

Architects. Information can also be found on 

the company website. 

www.steico.co.uk

Across the board coverage 

Technical Editor, Bruce Meechan hears from Ged Ferris of Cembrit about the wide selection of board products the 

manufacturer can offer for internal and external construction applications. 

The term one-stop-shop may be over 

used in the UK building products supply 

chain, but the range of boards offered 

by long-established manufacturer, Cembrit 

can provide specifiers with solutions to every 

sort of challenge from interior refurbishment 

and the creation of wet rooms within social 

housing units, to some of the most daunting 

logistical demands faced by burgeoning offsite 

or MMC sector. 

.The majority of the board options offer not just 

excellent physical characteristics, but a strong 

lineage and a long track record of service, both 

here and on the Continent. 

The SP board offers a very rapid means of 

effectively tanking a room 

As UK Marketing Manager, Ged Ferris, 

commented during our interview: “We have the 

product range to facilitate the needs of 

everyone from offsite system fabricators to 

refurbishment specialists and the growing selfbuild 

market. 

Not just a Five-star range, but a range with five 

main stars and many product variations: 

Cembrit’s flat boards encompass all the key 

performance parameters including moisture 

resistance, fire resistance and structural 

strength, as well as providing a versatile 

substrate for commonly used finishes. 

THE RANGE General purpose and specialist 

requirements solved by Cembrit’s boards 

The product within the range which has shown 

the most rapid growth across the market is PB: 

a versatile tile backer or render backer board, 

mainly being used for the refurbishment of 

bathrooms, it is popular due to its low weight 

and ease of cutting which facilitates 

installation, and the robust long term 

performance. Cembrit has developed a version 

called Flex which can be fixed down to radii of 

just 150 mm. Both conventional PB and Flex 

features polystyrene spherules and an edge 

reinforcement detail that uses a special fabric 

allowing butt jointing and fixings close to edges 

This Walsall project shows a 

typical sheathing application 

for Cempanel before final 

cladding is installed 

for maximum rigidity. Flex installations might 

then form a column casing that would be 

rendered over or covered with a small format 

mosaic. 

Where social housing providers are seeking to 

fit out full wet rooms for those who might need 

assistance with personal care, then there is also 

a Special Performance board which was 

originally developed for use in places like 

swimming pools. 

The biggest seller still, though in terms of 

volume is Cempanel which is primarily specified 

for dry-lining and sheathing: the internal skin to 

a rainscreen cladding build up. Depending on 

dimensions, Cempanel can also take racking 

Making the right board decision 

Cembrit FR Fire rated building board 

Cembrit Cempanel High strength panels for external 

sheathing in rainscreen cladding systems 

Cembrit HD Heavy duty external building 

board for agriculture and construction 

20

loads: being produced in thicknesses of 8, 10, 12 

and 16 mm. It is also often used as a render 

carrier in exterior applications. 

The Cembrit range of high performance board products is ideally suited to use 

by the offsite sector as well as for refurbishment and other applications 

The FR board can provide up to 120 minutes of 

fire resistance and is widely specified for soffits 

in corridors, lift lobbies and other communal 

“We see our board range as 

being of particular value to 

manufacturers of modules, 

pods, timber frame panel 

systems and other 

prefabricated solutions. 

They could even form the 

face to SIPs (Structural 

Insulated Panel) systems.” 

Ged Ferris, UK Marketing Manager, Cembrit 

Fire resistance approval testing on FR board 

areas to buildings where the consideration of 

escape routes and combating the surface 

spread of flame are essential. 

Ged Ferris added: “We see our board range as 

being of particular value to manufacturers of 

modules, pods, timber frame panel systems and 

other prefabricated solutions. They could even 

form the face to SIPs (Structural Insulated 

Panel) systems. 

“As well as the merchant stockist, clients can 

also purchase through ‘optimizers’ – board 

cutting specialists who supply the exact sizes 

they need to make our standard product 

PB Flex used as a tile backing 

coordinate with elevation widths, window 

openings and things like flues or other service 

penetrations. It will also be a real advantage to 

customers that such a comprehensive selection 

is available from a single source.” 

Responding to market demand, Cembrit is also 

making its cladding boards available as BIM 

objects in partnership with its Scandinavian 

parent company. These can be viewed via the 

company’s website at www.cembrit.co.uk or by 

contacting the company’s technical advisory 

service via email. 


couldn’t be easier with Cembrit. 

Cembrit PB Baseboard for external 

render or wet area tiling 

Cembrit Multi-purpose Easily cut board with good 

impact resistance for panels, strips and partitions 

With a range of boards that 

satisfy the requirements of most 

lining, panelling and baseboard 

applications Cembrit building 

boards are ideal for off site 

construction. Cembrit can 

supply mixed loads to ease your 

stockholding. 

Unit 1a, Normanton Industrial Estate, 

Nr Leeds W. Yorkshire WF6 1TN. 

T: 01924 890890 F: 01924 897487 

E: info@cembrit.co.uk www.cembrit.co.uk 

MMC November 2 2015 16:48 21

Spantherm - the insulated precast 

concrete ground floor system 

Thermal, structural, sustainable 

Spantherm is a pre-insulated precast 

concrete flooring system designed 

specifically for residential and mid sized 

commercial ground floors. The composite slab 

combines structural concrete and high 

performance Expanded Polystyrene (EPS) 

insulation to provide a superior thermal floor. 

Cavity Wall 

Insulation 

Spantherm Unit 

Why use Spantherm? 

• More efficient than beam and block 

• Faster installation on site 

• Excellent thermal performance with a U-value 

as low as 0.12 W/m2K 

• Provides a flat, safe working platform with all 

insulation below the structural slab 

• Eliminates cold bridging 

• Significantly reduces on site construction time, 

labour and waste 

• Structural floor ready to build off next day 

• No need for expensive storage for insulation 

• Install with existing plant and machinery 

DPC 

Localised 

Bearing Point 

Blockwork 

Support 

Grout 

Concrete 

Element 

Insulation 

Element 

The Complete Service Package 

Creagh Concrete, established in 1976, is one of the largest and most innovative producers of 

concrete products for a diverse range of market sectors throughout Ireland and the UK. 

The team offers a comprehensive design service which includes provision of CAD based 

drawings along with all relevant structural and thermal design calculations. On completion 

of the project, a design certificate will be provided along with calculations for your project. 

With bases throughout the UK, Creagh Concrete offers rapid nationwide delivery and 

exceptional customer service and flexibility. This ethos is combined with a diverse portfolio 

of products that showcases the limitless possibilities and potential of precast concrete. 

Visit www.creaghconcrete.co.uk/spantherm or email info@creaghconcrete.com 

for further information on Spantherm and the full product range 

22

The structural envelope 

has now been pushed 

ICF goes 

Offsite 

High Insulation Level 

High Strength 

High Build Speed 

But 

Low Cost 

Low Skill Levels 

With 

No Drama 

Polarwall www.polarwall.co.uk 0845 838 2181 


Acoustic Fire & 

Thermal > 

Simple airtightness 

solution is a BBA first 

Specifiers and architects looking for a 

straightforward but healthy and effective 

air tightness solution for buildings need 

look no further than Wraptite-SA. 

The abilities of this single-component, 

externally applied air barrier from the A. 

Proctor Group have now been officially 

recognised by the BBA following 

comprehensive assessment at its 

laboratory in Watford. The product makes 

a significant contribution to a building’s 

thermal performance by preventing 

lateral air movement, but also helps 

maintain a healthy living environment 

and structure thanks to its high vapour 

permeability rating (Sd 0.039). 

The self-adhering membrane fully bonds 

to virtually any substrate, requiring no 

mechanical attachment, seals or tapes to 

suppress air leakage around junctions or 

penetrations. 

Skanska specifies Cygnus for new city building 

The Monument Building in the heart of the City of London is one of the current projects to 

use Bull Products’ latest Cygnus wireless alarm system during construction works. Standing 

adjacent to The Monument, which marks the origin of the Great Fire of London, the 88,000sq 

ft office accommodation is split over ten floors with terraces at several levels. 

Skanska has been using the Bull Products system since 

construction started last year, specifying some 26 units. 

Intended purely for use on construction sites, the CE marked 

Cygnus system has been specifically designed for use in dense 

concrete and steel structured buildings and areas where there 

are many other radio frequencies in operation. 

The Cygnus alarm system can link as many as 480 alarm and 

detector units in different zones on a construction site, and 

individual units can be fire alarm call points, first aid alerts, 

combined call points and first aid alerts, smoke detectors, or 

heat detectors. 

www.bullproducts.co.uk 

Knauf Facades simplifies school construction 

Timely technical support reinforced with on-site 

inspections led to CRT Construction to choose SFS 

systems from Knauf Facades when engaged by Wates 

Construction in the project to build the £4.7 million 

Garston Manor SEN school in Watford. 

The single storey 3,000m2 building provides 120 

places for students aged 11 to 16 years and features 

flexible teaching spaces, food technology, art, drama 

and science areas, specialist sensory rooms and 

pastoral care units. 

All Knauf Exterior Wall Systems have been fully designed and tested for their structural, 

thermal, fire and acoustic performance in collaboration with UKAS laboratories and industry 

leading consultants such as the Steel Construction Institute (SCI). Fire safety is operational 

from the start, allowing for high levels of fire protection during construction, as well as once 

the project is complete. 

www.knauf.co.uk 

Wraptite-SA has received BBA 

certification (no. 15/5274) for use in both 

roofs and in walls behind the rain screen 

cladding making it an ideal choice for 

commercial projects with large 

uninterrupted facades. 

Key construction benefits: 

• Air tightness - as well as wind 

resistance during construction 

• Water resistance - providing 

temporary protection for the 

building fabric during construction 

• Breathability - allows vapour to 

escape reducing condensation for 

users and structure 

• One-piece solution – requires no 

tapes 

• Self-adhering- reduces mechanical 

fixings of the membrane and 

ensures less risk of water/wind 

without limiting vapour 

permeability 

www.proctorgroup.com 

Eurocell helps transform market into Nottingham’s 

Creative Quarter 

Technical support from Eurocell has contributed to the 

£3.85 million redevelopment of Sneinton Market that 

planners believe will transform it into the Nottingham’s 

own Covent Garden. 

Wates was appointed as main contractor to refurbish 

three of the five 'avenues' at Sneinton Market, funded 

through a £2.44m European Regional Development 

Fund (ERDF) grant and a further £1.45m from the City 

Council. And Wates selected Derbyshire Floorcraft to 

refurbish the 8 x 80m long lean-to roofs that are an integral part of the market’s particular 

appearance. 

“Eurocell provided outstanding service,” says Darren Scarborough of Derbyshire Floorcraft. “It 

modified one of its conservatory roof products and produced it in a bespoke colour, anthracite, 

so it was in keeping with the heritage nature of the site and sent its architect and design team 

to site to make sure it all fitted properly. The result is a design that matches the original 

Victorian design but delivers a 21st century performance.” 

www.eurocell.co.uk 

24

Totally drained... 

Range of products changing approach to modern methods of residential drainage 

“The systems have been specifically designed 

to provide flexible solutions to problems that 

face those building residential property every 

day. They meet the best-practice requirements 

of all current SuDS guidance and legislation.” 

Providing a more natural approach to managing 

rainfall, Skeletank is a Surface water drainage 

system (SuDS) that can deliver provide both 

infiltration and attenuation. Skeletank solutions 

are suitable for pervious, impervious and softlandscaped 

surfaces making them incredibility 

flexible in use. 

Designed to manage surface water run-off 

within the grounds of each individual property, 

the system can return the water to the ground 

and/or store the water before releasing it in a 

controlled manner to the mains sewer network, 

or adjacent watercourses. 

Arange of products is now proving 

popular with construction companies 

looking for innovative and modern 

methods following its launch earlier this year. 

Skeletank is now set to take the UK house 

construction market by storm, offering a 

solution to addressing the issues faced by 

residential builders when designing and 

installing surface water drainage systems. 

...Skeletank systems offer 

ground breaking design 

benefits to residential 

drainage schemes, 

gathering rainwater at 

source and allowing its 

controlled release... 

Providing innovative sustainable drainage 

systems (SuDS) designed specifically for 

residential properties, Skeletank is only 

available from Hydro Water Management 

Solutions (Hydro WMS) and is the first modular 

systems of its type in the UK. 

Adhering to the management train laid out in 

CIRIA C697, Skeletank systems bring with them 

26 

a host of benefits for residential developers, 

social housing companies, local authorities and 

construction companies. 

Potential benefits include releasing more land 

for development; substantial reduction in 

upfront costs of adoptable networks; improved 

cash-flow for developers; CDM and Health & 

Safety benefits and most importantly, the 

reduction of flood risk. 

Director of Hydro WMS Brian Byrne explains 

further: “Skeletank systems offer ground 

breaking design benefits to residential drainage 

schemes, gathering rainwater at source and 

allowing its controlled release, either naturally 

back into the environment, or into the sewer 

network at a manageable rate. 

This modern method of managing surface 

water run-off at source can reduce the up-front 

cost of adoptable networks and provide major 

cash-flow benefits to developers. It may also be 

possible to reduce the size of 

open water features on site, 

such as ponds, thus allowing 

more room for more 

properties on the same sized 

site. 

The main components of 

Skeletank systems are 

designed to be installed at a 

shallow level beneath 

hardened surfaces with 

minimal cover. This also 

proves extremely costeffective, 

especially where 

there are ground issues such 

as contamination, high water 

tables or underlying rock layers. This reduced 

excavation means that the CDM benefits are 

huge, and staff safety is looked after, which is 

important in the world of construction. 

Brian concluded: “It is an exciting time for 

Skeletank as more and more home builders are 

having to look for innovative ways to deal with 

water and there are now stringent SuDS 

guidelines to be followed. We not only make life 

easy, but we offer so many other benefits, that 

Skeletank is poised to be a market leader used 

by large and small private and public 

developers.” 

More information about the 

Skeletank range is available at 

www.skeletank.co.uk

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Article > 

Offsite construction – healthcare’s 

complete turnkey solution 

The capabilities of offsite more than match traditional build. Patient wards, theatres, A&E departments and 

cleanrooms can all be designed, built and delivered in just 12 weeks using modular methods of construction, 

reducing the need for interim short-term hire. 

> The extension has created six, six-bed wards and 15 single bedrooms 

with several link corridors to improve circulation within the hospital. 

For the first time, many healthcare 

establishments are considering offsite 

construction because of its costeffective 

nature and the efficiencies it 

provides. 

Matthew Goff, UK Operations Director at 

Actavo | Building Solutions – formerly known as 

Roan Building Solutions – explains how 

Business Information Modelling (BIM) has been 

integrated into offsite methods of construction 

and the benefits it provides. 

BIM – providing insight into the future of 

healthcare 

With many NHS trusts already in debt and the 

whole service facing unprecedented financial 

challenges, the introduction of BIM offers some 

hope for estates managers looking to deliver 

savings while enhancing quality. 

Actavo | Building Solutions is one of the first 

offsite construction companies to meet BIM 

Level 2 and it has been fully integrated into the 

business since June 2015. Instrumental in 

winning new business, Actavo | Building 

Solutions can now showcase the true benefits 

of offsite build as a quick, cost-effective and 

high-quality solution. 

Modular buildings can now be built to any 

specification – BREEAM, Passivhaus or AECB. 

As BIM helps extend design life, it can exploit 

advances in materials and improvements in 

sustainability and energy efficiency. 

than traditional build – which impacts on bed 

availability. 

Modular build is making the construction 

industry safer due to shorter construction and 

build times – just four weeks in some cases – as 

well as the buildings being manufactured in 

more quality controlled environments. These 

factors combine to make it easier for estate 

and facilities managers to plan and re-direct 

resources. 

New build case study: paediatric wing 

Cork University Hospital, Ireland, has added a 

brand new, single-storey €3.4m paediatric wing 

to its centre of excellence with a design and 

build project delivered by Actavo | Building 

Solutions. 

The extension sits on top of the ground floor of 

Cork University Hospital and has created six, 

six-bed wards and 15 single bedrooms with a 

total 1600m2 of additional floor space and 

several link corridors to improve circulation 

within the hospital. 

The Cork University Hospital extension was 

difficult to reach as it is located above a 

working ward within a courtyard and with 

limited road access. Even so, the new 

paediatric wing was completed in June 2015 

and took just 26 weeks to complete using 

modular methods of construction, meaning 

that 80% of the programme took place offsite. 

Actavo | Building Solutions also mirrored the 

existing external brick slip front so the 

extension was aesthetically-attuned with the 

rest of the hospital, as well as also fitting a 

pneumatic drug circulation system to both the 

new and existing building. 

Environmental design features included 

measures to support air-tightness and sound 

insulation. 

www.actavo.com 

However, where offsite comes into its own is 

the cost-saving delivered through speed of 

delivery – sometimes up to 50 per cent quicker 

> Cork University Hospital’s new modular, first-storey, paediatric wing was completed 

in just 26 weeks and mirrors the external brick slip front of the original building. 

28

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while minimising down time and waste. 

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ICARUS L.S.F. PROJECT

Article > 

New ‘super school’ built offsite 

MMC Magazine looks at how the London Borough of Barking and Dagenham has embraced factory fabrication to help 

meet its rapidly rising need for education places. 

The 23,000 square metre Riverside Schools scheme is one of the largest 

education projects now under construction and will provide additional 

places for one of the fastest-growing school-age populations in the UK. 

Barking and Dagenham has one of the highest 

growth rates of school age children, driven in 

part by an ambitious housebuilding programme 

which is already under way. As a result there is 

the need for the primary school and SEN 

facilities to be delivered ahead of the rest of 

the campus, with these being set to open in 

time for the start of the next academic year in 

autumn 2016. The flexibility of the Yorkon 

offsite solution is making this not just possible, 

but practical - while the whole project is due for 

completion in spring 2017. 

The pressures on the UK’s education 

system are well documented and 

increasing, but the solutions far less 

evident. However, in East London the Yorkon 

Group company, Portakabin has been 

instrumental in helping deliver what is 

believed to be the largest ever offsite contract 

in the education sector.. 

The Riverside Schools scheme in the London 

Borough of Barking and Dagenham covers 

23,000 square metres and stretches from 

nursery to age nineteen across three free 

schools, with the £44 million cost coming from 

the Education Funding Agency. Portakabin’s 

contract for all of the “curriculum spaces” was 

awarded via the council’s Thames Partnership 

for Learning. 

When complete the campus will accommodate 

a 10-form entry secondary school, a 630-place 

primary school, a special educational needs 

(SEN) school, and a nursery. It will also offer 

extended provision outside school hours as well 

as wider use at weekends and during school 

holidays; to contribute to the local community. 

Roger Leighton is Chief Executive of 

Partnership Learning which will operate the 

three schools on the campus, and commented: 

“We have had a very good first-hand 

experience of the Portakabin Group’s offsite 

solutions as our schools currently occupy two 

earlier phases on a site near the planned 

Riverside Schools campus. We have been really 

impressed with the quality of the finished 

buildings, the speed of construction, and just 

how far offsite technology has now advanced. 

“The Portakabin Group makes good use of 

architectural design to the benefit of the users 

and to enhance the internal environment. As 

an example, our strong preference is for 75 

square metre classrooms which are 

significantly larger than the 56 square metre 

classrooms required by the Department for 

Education. With careful design and planning, 

use of a Yorkon offsite solution gives us the 

flexibility to achieve this and for almost the 

same budget – which is a very key benefit.” 

Speaking to MMC Magazine during the Offsite 

show at London’s Excel Centre, Simon Ambler. 

Director of the Portakabin Group said: “We 

have been building a very good relationship 

with the London Borough of Barking and 

Dagenham – this is our seventh project for the 

council. The contract demonstrates how the 

Yorkon building solutions can be employed to 

meet the urgent need for school places, and 

early engagement here has been important 

because of the borough’s desire to build to nonstandard 

sizes.” 

The group has invested in a new plant in York 

which feature’s Europe’s largest press for such 

systems, while also developing a new system 

that is not only flexible in terms of its space 

dimensions but also the way it can link to 

existing buildings 

Simon Ambler concluded: “We expect this 

project to change the face of off-site 

construction in the education sector.” 

www.yorkon.co.uk 

“The Portakabin Group makes good use of architectural design to the benefit of the users and to enhance the 

internal environment. As an example, our strong preference is for 75 square metre classrooms which are 

significantly larger than the 56sqm classrooms required by the Department for Education. With careful design and 

planning, use of a Yorkon offsite solution gives us the flexibility to achieve this and for almost the same budget.” 

Roger Leighton, Chief Executive of Partnership Learning. 

30

Engineered solution > 

...with a certified performance designed to overcome 

skills shortages & meet building regulations 

Article > 

As widely reported, the recession caused a vast fall in the demand for bricks, resulting in many kilns ceasing to 

manufacture and bricklayers having to find alternative employment. As the industry emerged from the downturn, 

in 2014, it became clear that housebuilders were challenged by two major factors - a shortage of materials and 

traditional labour skills. 

Although many businesses grappled to 

find the best way forward, Alumasc 

Facade Systems turned this situation 

into an opportunity by developing a new and 

innovative facade technology designed 

specifically for the offsite structural timber 

sector – the Alumasc Ventilated System 

(AVS). 

AVS meets all UK ventilation standards for 

timber framed buildings and offers an 

industry-leading A2 Fire Performance Rating, 

together with the highest levels of impact 

resistance and is suited to all exposure levels. 

AVS complies with the requirements of both 

the NHBC and TRADA, namely the need for 

ventilation for structural timber construction, 

with a minimum of 15mm ventilated cavity for 

NHBC and 25mm for TRADA. 

The system accommodates a range of cavity 

depths - the free-flowing system ensures that 

the substrate remains continuously ventilated 

and prevents any moisture tracking back to 

the primary structure, removing condensation 

– providing a protective facade. 

Offering an alternative method of 

construction, AVS can replicate any brick in 

the market via patented, lightweight acrylic 

brick slips. The system is not just limited to 

using acrylic brick slips as the final facade 

Technical Approval 

The AVS system has been rigorously tested, 

resulting in compliance with all UK Building 

Regulations and became British Board of 

Agrément approved (Cert No: 15/5211) in May 

2015. It is the only ventilated system in the UK 

to be BBA certified with an external acrylic 

The initial product development remit was to 

design a ventilated system that would 

replicate traditional building aesthetics, whilst 

providing a lightweight solution that could be 

fixed directly to structural timber systems. 

Alumasc’s main goal was to ensure the system 

was engineered to deliver structural stability 

across all applications whilst providing 

adaptability to all forms of structural timber 

construction. 

This innovative, engineered system provides 

the solution to overcome the fundamental 

issues of the brick shortages. AVS, as an 

offsite manufactured system, improves 

efficiency and speed of construction, 

addresses skills shortages and enhances the 

quality of finish, whilst delivering the final 

aesthetics to meet the exacting requirements 

of architects, designers and housebuilders. 

The product offers specifiers a ventilated 

cladding solution for timber frame 

construction (open and closed panel 

technology), together with volumetric 

modular and structurally insulated panel 

systems (SIPS). It protects the fabric of the 

building whilst providing a wide choice of 

aesthetic options. 

finish - it is also approved for use with 

textures, through-coloured silicone renders, 

along with an extensive range of dashing 

renders. 

AVS is erected via Alumasc’s network of 

registered installers to ensure correct 

application onsite. The AVS installer training 

programme is independantly assessed and 

approved by the BBA. AVS comes with a 10 

year warranty offer for all projects installed 

by an Alumasc registered contractor. 

brick slip finish and offers an industry-leading 

A2 rating, providing the building with 

improved fire performance when compared to 

other cladding solutions. 

During the development of the system, 

Alumasc worked very closely with a number 

of companies and bodies to ensure AVS would 

meet the demands of the offsite and onsite 

construction industry, whilst providing 

optimum performance and longevity. These 

organisations include CCG, Exova Fire 

Research, Warrington (fire testing); Lucideon 

(UKAS accredited testing body); Pell 

Frishmann (Consultant Engineers) and the 

British Board of Agrément. 

AVS is the solution to overcome current 

construction industry skills issues and is wellpositioned 

to be part of the building 

technology of the future. 

To book a CPD seminar please email: 

facades@alumasc-exteriors.co.uk 

www.alumascfacades.co.uk/avs 


Article > 

Building fabric in the firing line 

Technical Editor Bruce Meechan reports from the Inmarsat Centre in London about a wide ranging conference 

staged there on November 18th. 

and perhaps this points to why so many of our 

modern or recently overclad properties suffer 

from condensation problems. 

Several of the speakers touched on the subject 

of dwellings overheating, with the various 

remedies recommended including greater use 

of thermal mass and concrete or masonry 

elements, better attention to the detailing and 

construction of ductwork serving MVHR or 

other ventilation systems, and also solar 

shading or shutters. 

There have been many times when I have 

sat through a chairman’s opening 

remarks at a construction conference 

and wondered if I wouldn’t have been better 

hanging around in the foyer for a second cup 

of tea – but not so with what Rob Pannell from 

the Zero Carbon Hub had to say at the Fabric 

First event, staged in London’s very 

accessible Inmarsat Building by Radar 

Communications. 

While I don’t share the Zero Carbon Hub’s 

certainty about Global warming, amongst his 

many observations that struck a chord with me 

were that Government has failed to show any 

real leadership on energy matters, whilst “firing 

shots all over the place”; and also that he would 

like to have a meeting with Minister Amber 

Rudd, to “explain to her what Fabric First 

means.” 

Mr Pannell also shares my scepticism over the 

value of Energy Performance Certificates or 

EPCs; though while I believe they are not nearly 

specific enough in assessing the nature of the 

building fabric, his view is based on the fact 

that buildings are failing to reach their target 

standards. 

In his own recently constructed home there are 

apparently draughts coming from behind the 

electric sockets; while a later speaker 

expressed the view that because the UK’s 

climate is relatively mild we simply can’t be 

bothered to get our buildings right. If that is the 

case, achieving the Government’s commitments 

on carbon reduction really is going to be a 

problem. 

This disturbing perspective came from Gordon 

32 

Alistair Donn, Willmott Dixon and 

Kim Mead, Passive House Trust 

during the afternoon Q&A sessions 

Evans of the YOOP Architectural Practice who 

insisted that the Canadians build far better 

than us – in particular achieving very good 

airtightness and continuity of insulation – 

despite targeting less onerous U-values than 

are routinely used in the UK. 

Gordon Evans of the YOOP 

Architectural Practice 

considers that the Canadians 

build far better than us – in 

particular achieving very 

good airtightness and 

continuity of insulation – 

despite targeting less 

onerous U-values than are 

routinely used in the UK 

Although Gordon presented an overview of the 

Boxtree social housing development in Harrow, 

which has won many awards and so impressed 

the INCA judging panel I was on, he cited a 

variety of projects from around the globe that 

his practice has been involved on. Struck by the 

variety of building solutions they had used – 

including ICF and timber frame – I asked him 

during the Q&A session about the importance 

he and his colleagues put on local climate in 

relation to such decisions. 

His response was unambiguous, commenting 

on one which was internally insulated to 

counter the predominantly humid conditions, 

Kym Mead gave one of the afternoon’s best 

presentations on behalf of the PassivHaus Trust 

– those most airtight of buildings – and 

surprised many of us by reporting that the UK 

has only recently passed the 300 mark in terms 

of fully certificated projects. He did point out, 

however, that a block of flats counts as just one 

PassivHaus property. 

He also asserted that: “Done properly, a 

PassivHaus building will not suffer overheating 

in summer.” 

While the whole event was well worth the 

attention of those present – and it seemed 

many had decided not to attend due to the 

heightened security fears in London after the 

attacks in France – the case studies were 

probably of most value to delegates. 

Alasdair Donn of Wilmott Dixon for instance, 

talked about the Centre for Medicine at 

Leicester University which has been built to 

PassivHaus standards, and offered numerous 

insights into such issues as insulating bracketry 

and the need to carry out air leakage testing on 

zones as the structure progresses. 

We will cover some of the systems being shown 

in the accompanying exhibition in our January 

edition. 

The Inmarsat Centre sits above Old Street 

Tube station on City Road and is an ideal 

facility for conferences of this size.

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Protect Membranes launches Party 

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Sale, UK – 12 November 2015 – Protect Membranes Limited have 

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The pack, comprising a 300mm x 25m Protect party wall air 

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of heat loss from party walls in timber frame buildings. 

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Article > 

‘Traditional’ approach to island 


MMC Magazine’s Bruce Meechan reports on a substantial low energy development by one of the south-east of 

England’s largest housing associations. 

Many of our readers will be aware of 

the Isle-of-Wight’s desire to become 

a Zero Carbon beacon for other 

parts of the country – by maximizing the use 

of renewable energy sources as well as 

cutting usage across its properties – but the 

ambition has been brought a step closer 

thanks to the decision of Southern Housing 

Group to build 28 new homes to PassivHaus 

Standard. . 

Cameron Close in Freshwater on the island’s 

western side is a £4.2 million development of 

16 semi-detached family homes and a dozen 

sheltered apartments; built on a 1.5 acre site 

formerly occupied by an earlier retirement 

scheme belonging to the RSL. 

Interestingly, the development began its life 

being designed by PCKO Architects to satisfy 

the higher levels of the Code for Sustainable 

Homes, before Southern Housing Group’s 

Regional Manager viewed another PassivHaus 

project in Portland, Dorset and recognised the 

potential for doing the same at Cameron 

Close. 

As Alan Townshend, Development Director at 

Southern Housing Group, explained to MMC 

Magazine: “We decided to make Cameron 

Close a PassivHaus development as it best 

meets the group’s sustainability objectives 

without the need to provide expensive 

renewable technology. We moved our current 

residents to a new modern sheltered housing 

scheme, Whitmore Court, that best met their 

needs and used the existing site to create 

those environmentally friendly family homes. 

“As part of our aim to provide sustainable 

tenures, the group is always looking at how we 

can improve the quality of the homes we 

provide, so not only does this ‘fabric first’ 

approach provide an environmentally friendly 

solution for building these homes, it will also 

give the residents of Cameron Close 

significant and long-term savings on their 

energy bills. 

“When we decided to go down the traditional 

route rather than timber frame, Celcon was 

approached, and it was the company that 

suggested thin-joint construction as the best 

solution. Celcon was very helpful with 

technical guidance and providing training for 

the operatives from Stoneham Construction 

on the Isle-of-Wight who were going to lay the 

thin-joint system.” 

The exterior walls were finished with a 

proprietary render system applied to 230 mm 

of insulation, fixed over the 200 thick Celcon 

blockwork. This was parge coated on the inside 

in order to achieve an excellent level of 

airtightness – typically 0.48 m3/m2/hr at 50 

Pascals. The contractor then formed a metal 

studded batten cavity behind a final lining of 

plasterboard which provides a service void. 

Also of major importance to controlling air 

leakage was the selection of triple glazed, 

aluminium clad windows from Munster Joinery, 

and exterior doors manufactured by Internorm. 

Then at first floor ceiling level, a polythene 

membrane was installed above the 

plasterboard soffit. Overall the success of all 

these measures is also the result of a 

‘PassivHaus Champion’ having been employed 

on site to monitor all of these details’ 

execution; along with the multiple service 

penetrations. 

The ground floor construction features the use 

of a beam and block floor system, overlaid with 

250 mm of Kingspan Kootherm K3 insulation 

and then a further concrete slab which also 

helps add thermal mass to the living space. 

Of course the main idea of using such high 

levels of insulation in a PassivHaus 

construction is to keep energy usage down to a 

very low level; and often you will find properties 

just feature a wood burning stove to ‘top up’ 

the heating on the coldest days. At Cameron 

Close, the solution chosen was to give every 

home a small combination boiler to not just 

supply the kitchen and bathroom with hot 

water, but also to heat a towel rail and a couple 

of radiators. One is in the hallway while another 

is situated in the lounge; offering visual 

comfort as much as physical warmth. Zehnder 

Comfoair MVHR units are also installed in every 

home to further reduce heat loss and ensure 

necessary air changes are achieved. 

Work actually started on site in early 

September 2013 with final planning permission 

having been granted in the previous December, 

before going through the OJEU tendering 

process. Alan recalled: “The tenders for 

building to PassivHaus standards actually came 

back higher than we had expected, but we had 

already secured HCA funding and the Isle-of- 

Wight Council also provided some finance to 

support the PassivHaus element to the build as 

it was in line with their Green Island agenda. 

“Our initial estimation is that the entire 

scheme could save up to £25,000 a year in 

energy costs, with some residents being able 

to save up to £900 in a three bedroom home.” 

The PassivHaus Institute has already precertified 

all fixtures and fittings to ensure that 

the required heating and primary energy limits 

are met; the homes are currently going 

through the PassivHaus certification process. 

Alan concluded saying: “If we were going to 

develop another PassivHaus project I think we 

might well use the thin-joint masonry again, as 

it proved very successful, though we would 

probably revert to a traditional brickwork 

outer elevation as the render proved difficult 

to apply in the poor weather conditions 

suffered.” 

The properties are now the subject of post 

occupation monitoring using heat meters and 

other sensors. 

• Over the last 110 years, Southern Housing 

Group has become one of the largest 

housing associations in the south of 

England, housing more than 67,000 

residents, managing almost 30,000 

homes, employing nearly 900 people and 

working with more than 70 local 

authorities across the South East, 

including the Isle of Wight. 

• Our vision, ‘A business with social 

objectives’, draws on our history and 

traditions while recognising the need to 

change with changes in the housing 

sector. 

• Our social and economic regeneration 

work is undertaken to improve the lives of 

residents in the communities and 

neighbourhoods where we build and 

manage homes. It provides tangible 

evidence of our commitment to building 

sustainable communities. 

• Southern Housing Group is a member of 

the g15, which represents London's 15 

largest housing associations. The g15 

houses one in ten Londoners and builds a 

quarter of London's new homes. We are 

working to solve the housing crisis by 

delivering good quality, affordable homes 

of all types. To find out more about the 

g15's work please visit g15london.org.uk 

34

“As part of our aim to provide 

sustainable tenures, the group is always 

looking at how we can improve the 

quality of the homes we provide, so not 

only does this ‘fabric first’ approach 

provide an environmentally friendly 

solution for building these homes, it will 

also give the residents of Cameron Close 

significant and long-term savings on 

their energy bills.” 

Alan Townshend, Development Director at Southern Housing Group 


Article > 

ErP means level playing field for heating 

Mitsubishi Electric has produced a free, CPD-accredited guide to the new Energy Related Products Directive or ErP 

(2009/125/EC), which is a key part of the European Union’s drive to encourage consumers to use more energy 

efficient products. 

To highlight the requirements under ErP 

the company has also released a short 

video which explains how the Directive 

is designed to help phase out lower 

performing products whilst having a positive 

impact on the emissions levels across Europe 

and increase the share of renewable energies 

by 20 per cent. 

The ErP Directive, which came into force at the 

end of September 2015, now means that 

commercial and residential heating products 

will need to display an energy label, so that 

consumers can quickly understand the energy 

efficiency of the products they purchase. 

A similar market transformation strategy has 

already proved highly successful with consumer 

goods such as fridges and freezers, where it is 

now very rare to find anything below an A rated 

product available on the high street. 

“There are two parts to the ErP strategy which 

affect both manufacturers and installers and 

everyone involved needs to understand how 

this will change the heating market”, explains 

Max Halliwell, who fronts the video on behalf of 

the company. 

Firstly, the ErP requires manufacturers to 

produce energy-using products that meet 

stringent minimum performance standards. 

And secondly, these products must be clearly 

labelled using a standard methodology so that 

consumers can quickly understand the energy 

efficiency of the products they purchase. 

These labels will show the efficiency ranging 

from the most efficient A++ to the least 

efficient G and will be clearly marked with 

coloured bars; from green (the most efficient) 

all the way down to red (least efficient). 

36 

The details on the label will identify the 

efficiency band for heating, and where relevant, 

hot water production and where relevant, noise, 

emissions and power consumption. 

“For heat pumps they will also indicate the 

three different climate zones within Europe 

which is important 

here because the 

UK is split 

between all three 

of these zones”, 

adds Halliwell. 

“We feel that 

this is now 

levelling the 

playing field for 

heating 

products which 

will allow 

consumers to 

see exactly 

how energy 

efficient the types of 

heating they choose are”. 

ErP is a significant piece of legislation that will 

have a major impact on the sale and use of 

heating systems in the UK. As such, the 

requirements of ErP is already being embedded 

into legislation on the energy efficiency of 

buildings and as incentive schemes for 

renewable technologies. 

In order to apply for Renewable Heat Incentive 

(RHI) payments, heating systems will now 

needs to comply with the Microgeneration 

Certification Scheme (MCS), which sets 

industry standards for products used to 

produce heat from renewable sources. 

In May 2015, the MCS published a new seasonal 

coefficient of performance (SCOP) calculator. It 

also updated its Installation Standard for heat 

pumps as a direct result of the introduction of 

ErP. The introduction of this SCOP calculator 

will enable certification bodies to use a 

standard method based on ErP to establish 

whether a heat pump is compliant. 

“This is important because in the past, the 

efficiency of a heating system was based on 

what is known as the coefficient of 

performance or COP”, explains 

Halliwell, “but this 

shows a single point in 

time, which is never a 

good indication on how 

efficiently it will perform 

all year round, whereas 

SCOP shows the 

performance across the 

different seasons and 

gives a much more 

accurate indication of 

efficiency”. 

The dedicated video can be 

viewed at the company’s 

YouTube Channel and 

further information on the 

entire range of A++ heat pumps can be found 

on the dedicated Youtube channel at 

youtu.be/4tzKoyzRMOU or at ecodan.co.uk. 

The CPD Guide covers both main parts of the 

ErP: the EcoDesign regulations and the Energy 

Labelling regulations. The guide explains how 

the labelling is designed to help businesses and 

homeowners understand the benefits of each 

technology and focuses on the importance of 

ErP in relation to legislation such as the 

Renewable Heat Incentive (RHI). 

Visit library.mitsubishielectric.co.uk and click 

on CPD Guides to download a version.

The Renewable Solutions Provider 

Making a World of Difference 

Clearly A ++ great 

way to lower 

your fuel bills 

The entire range of Ecodan heat pumps has been awarded an A ++ ErP 

rating – the new standard for energy effi ciency. Ecodan clearly offers a viable, 

low maintenance, cost effective alternative to traditional heating systems, so 

there has never been a better time to switch to a cleaner, greener heating 

solution that also qualifi es for the Renewable Heat Incentive. 

Ecodan. Clearly efficient, clearly renewable. 

For further information call 01707 282880 

or visit ecodanerp.co.uk/homeowner 

Ecobuild supports delivery of infrastructure revolution 

with new ice partnership and zone for 2016 

A new partnership between Ecobuild, the UK’s leading event for the construction industry, and the Institution of Civil Engineers 

(ICE) has been launched today ahead of the 2016 Ecobuild conference. The partnership will focus around a major new conference 

and exhibition centre – The Infrastructure Revolution Hub – which will enable industry to come together and discuss ways it can 

maximise the opportunity for growth, following Government’s commitment to infrastructure as key economic driver. 

At the heart of the Hub will be a large 

conference area which will debate the 

key issues for the infrastructure 

sector across the three days of Ecobuild. The 

Hub will also feature products and services 

key to this growth sector and the ICE genius 

networking bar, making it one of the key 

destinations at Ecobuild for infrastructure 

professionals looking to make connections 

with the people that matter. . 

TThe infrastructure seminars held in the 

Infrastructure Revolution Hub will feature the 

UK’s leading contractors and industry experts. 

With a mix of keynote speakers and panel 

sessions, the seminars will focus on future 

challenges, opportunities and global best 

practice. Discussions will cover three overall 

themes - ‘Creating the infrastructure of the 

future’, ‘Small cities’, and ‘Modelling climate 

change’, including decarbonising urban 

infrastructure, energy generation, unlocking 

private capital, bespoke planning, collaboration 

opportunities, modelling demand of growing 

populations, and flood risk management and 

mitigation. 

The partnership between ICE and Ecobuild 

follows Government’s announcement of a 

National Infrastructure Commission – an 

independent body that will enable longer term, 

strategic decisions to be made on 

infrastructure. Government has also committed 

to investing £100 billion in new infrastructure 

projects in this parliament. The industry has a 

crucial part to play and the new Infrastructure 

Revolution Hub will bring the key players 

together to drive forward change and 

innovation. 

Leading architect and member of the new 

National Infrastructure Commission, Sadie 

Morgan, will also be delivering a session on day 

two of the Ecobuild 2016 conference. 

Nathan Baker, ICE’s Director of Engineering 

Knowledge, said: “The societal benefit of 

effectively procured and managed 

infrastructure is immense. The need for 

increased collaboration, innovation and 

managing risk has never been higher than 

today. To create sustainable infrastructure, it is 

essential that we embrace new methods of 

working, increase the use of technology and 

new materials and develop a highly skilled, 

diverse workforce. The new Hub will help to 

bring these challenges and opportunities to the 

fore and encourage positive action to be 

taken.” 

Martin Hurn, Ecobuild Event Director 

commented: “The infrastructure sector is a key 

driver of construction industry growth with the 

Government putting a major focus on delivery 

of infrastructure pipeline projects, and the 

recent strong output figures boosted by the 

new Commission pointing to sustained 

performance. The new Hub will enable the 

sector to come together in 2016 and have the 

conversation around the shared agenda for 

delivery of the Infrastructure Revolution.” 

Ecobuild 2016 takes place at ExCeL, 

London from 8th to 10th March 

2016. For further information about 

Ecobuild 2016 please visit 

www.ecobuild.co.uk 


Article > 

Shackerley’s engineered stone façades 

shape up beautifully at Kew Bridge West 

Shackerley has demonstrated the extraordinary design potential and versatility of its Sureclad ® ventilated cladding 

offer by supplying an innovative engineered stone façade system for a challenging installation at Kew Bridge West, 

an exclusive development of 336 luxury apartments in North London. 

Two circular towers presented a major technical 

challenge for Shackerley and Stanmore 

Curved facade panels have been cut from solid blocks of engineered stone and specially prefabricated 

Prefabricated engineered stone façades 

Shackerley has supplied 2400m 2 of fully 

prefabricated Sureclad ® engineered stone 

cladding for the lower storeys of the nine 

apartment buildings that form this stunning 

complex, designed by Stockwool and developed 

by St James, part of the Berkeley Group. 

The engineered stone, in a natural limestone 

colourway and honed finish, provides a 

premium quality aesthetic at eye level 

throughout the development, contrasting with 

the lighter coloured insulated render of the 

upper storeys. 

Large format curved panels 

Two of the buildings feature circular towers 

calling for smooth and flawless rounded 

façades, which presented Shackerley and Kent 

based specialist façade installation contractor 

Stanmore with a significant technical challenge. 

Shackerley’s Sureclad ® Hang On system had to 

be customised to cater for large format curved 

panels, cut to a radius from solid blocks of 

engineered stone. Additional challenges 

included the design of elegantly faceted 

façades, using more traditionally formatted flat 

panels, to clad curved elevations of adjacent 

buildings, designed to reflect the ‘horseshoeshaped’ 

design of the complex. 

Close collaboration 

Because of the very individual nature of this 

project, and in particular the use of curved 

large format engineered stone, Shackerley and 

Stanmore worked very closely together to 

ensure the developer’s requirements were met. 

Bespoke solutions were required at every stage, 

from the design of the Sureclad ® façades to the 

meticulous scheduling and non-standard 

palletisation of the prefabricated system for 

safe delivery to site. To ensure the installation 

went smoothly, Stanmore’s installers also 

visited Shackerley to receive expert training in 

the use of the Sureclad ® system. 

Testing to NHBC criteria 

As this was the first time that the Sureclad ® 

system had been used in conjunction with 

curved engineered stone panels, the two 

companies arranged for the bespoke Sureclad ® 

system to be tested at VINCI Technology Centre 

UK where it was shown to meet all NHBC 

criteria. 

Successful installation 

Stanmore Commercial Director Peter Baker 

said: “We were responsible for delivering all the 

external façades, curtain walling, doors, 

windows and other external finishes on this 

project but the engineered stone cladding was 

by far the most highly valued element of the 

job. Close collaboration with our supplier was 

absolutely crucial. We hadn’t worked with 

Shackerley or its Sureclad ® façade system 

before, and it was also the first time that either 

party had worked with curved engineered stone 

panels, so there were many challenges to 

overcome. 

“However, by meticulously planning and 

modelling the installation and working hand in 

hand with Shackerley’s technical team, we 

achieved superb results for our client. The 

overall experience was very positive and we’re 

looking forward to working on other Sureclad ® 

projects in the future.” 

Award winning development 

Construction Director at St James, Brian 

Paterson, commented: “It was only when we 

came to value engineer the Kew Bridge West 

project that Shackerley’s system was brought 

to our attention. As a result of switching the 

engineered stone specification to Sureclad ® , 

we’ve undoubtedly benefitted from a more 

flexible and lighter façade solution than 

originally planned and, most importantly, from 

38

Faceted cladding was installed to reflect the horseshoe shape of the development 

very substantial cost savings, whilst still 

achieving our architects’ original design 

intention. 

He concluded: “We’re delighted with the results 

and the project has received very favourable 

feedback from colleagues throughout the 

Berkeley Group. The quality of Kew Bridge 

West has also been recognised within the wider 

industry, and in October, St James received an 

NHBC Seal of Excellence Award for achieving 

the highest standards in house building at this 

prestigious development.” 

“...As a result of switching 

the engineered stone 

specification to Sureclad ® , 

we’ve undoubtedly 

benefitted from a more 

flexible and lighter façade 

solution than originally 

planned...” 

Shackerley’s engineered stone façades clad 

the lower storeys of the development 

Sureclad ® versatility 

Shackerley has successfully clad hundreds of 

buildings, including many high profile 

developments, with its Sureclad ® ceramic 

granite cladding façade systems and is the 

clear market leader in the UK. Highly 

specialised manufacturing facilities at its ISO 

9001 certified factory include bespoke diamond 

tipped undercut drilling machines that provide 

recesses for undercut anchors that are used to 

prefabricate every Sureclad ® façade panel. As 

the Kew Bridge West development shows, these 

facilities are now being employed to 

prefabricate large format engineered stone, 

including curved façade panels, in exactly the 

same way, for installation as part of a Sureclad ® 

system. 

For further details on the Sureclad ® system 

please contact Shackerley on 0800 783 

0391 or visit www.shackerley.com 

Kew Bridge West, a stunning award winning development comprising nine individual apartment buildings 


The Great Debate – Is Offsite Construction 

the answer to the delivery challenge faced 

by the UK Construction Industry? 

With turnover predicted to reach £7billion by 2018 has the offsite construction sector finally found a place on the 

mainstream construction agenda? Could it indeed make the difference to the UK construction industry in its quest 

to deliver 200,000 new homes per year as well as new schools, student accommodation, and commercial buildings? 

Mike Stevenson 

The answer to these and other questions 

were the topic of two very lively 

debates at the recent inaugural offsite 

construction show. The debates were hosted 

by The Fabric First Academy, for whom Mike 

Stevenson Development of founding partner 

Sidey set the scene.. 

“Being at an offsite construction show seemed 

to us to be the ideal opportunity to debate the 

merits of offsite construction in the context of 

the wider industry, the challenges it faces, and 

the positive benefits it can deliver to the UK 

construction industry as it seeks to deliver 

unprecedented levels of new homes, student 

accommodation buildings, schools and 

commercial buildings”. 

“What we didn’t want was simply advocates of 

offsite construction saying how good it was – in 

fact we wanted the opposite. We wanted to find 

out what a cross section of industry people 

really thought about it; I think it is fair to say 

that those who attended didn’t go home 

disappointed, and hopefully they went away 

with more information and knowledge than 

they came with”. 

“Indeed knowledge is a great place to start. We 

asked the question as to why – although the 

offsite sector is on course to hit £7billion by 

2018 – there was still a resistance or reluctance 

to engage with this method of construction 

amongst so many”. 

“The view from the panel was that there was a 

real knowledge gap when it came to offsite 

methods and understanding the achievable 

benefits of building this way. Starting right at 

the beginning with architecture and design it 

was recognised that offsite did not form a big 

enough part of their learning, and very few 

architect’s practices actually design with offsite 

in mind from the outset; more so the appointed 

contractor looks at already agreed designs and 

only then see if offsite construction methods 

might be suitable to bring the scheme to life”. 

“This is a really key point; with so many sites 

now in tight inner city and urban locations the 

restrictions are such that building traditionally 

is often at best extremely difficult & 

problematic but at times just unfeasible. It is 

these restrictions – unaddressed at the outset – 

which can lead to costs running away from the 

agreed budget, and delivery times slipping 

away”. 

“For clients facing the twin pressures of budget 

constraint and needing to deliver quickly 

budget slippage is simply not acceptable, and 

neither is late delivery with the demands upon 

them to provide accommodation for a growing 

population in need of their support. Indeed it 

is the very essence of what offsite construction 

can bring – cost and delivery predictability 

which is seeing more and more people sit up 

and take notice”. 

“Stemming further from this was a realisation 

that the often spoken about labour and skills 

shortages are now really starting to bite, hitting 

not only on site, but actually in roles which are 

responsible for the design and development 

stages of building in the first place. Again, the 

same message - there is a knowledge gap to be 

filled as well as a skills gap. And talking of 

skills, according to the panel the UK 

construction industry is facing a loss of 

700,000 construction personnel over the next 

five years through entirely natural processes”. 

“The view was that delivering through offsite 

construction can reduce the labour 

requirement on any contract by up-to 25%, a 

number which could rise further as more 

construction is done this way”. 

“But perhaps the biggest debate was why does 

there appear to be such a resistance at 

constructor level to engaging with offsite and 

then seeing it through to delivery? Clearly 

40

there are many of the major construction 

companies now exploring offsite fully as they 

start to understand the benefits of cost 

predictability and delivery against those of 

traditional building methods and the need to 

guarantee their clients exactly what they ask 

for to an acceptable standard, on time and to 

budget”. 

“Coming out loud and clear from the debates 

was the on-going disconnect between design 

teams and construction teams. Too few of the 

buildings which are developed for offsite 

construction actually reach the site stages still 

as offsite manufactured schemes; yet the 

implications of this have been proven to be 

significant – with disappointed clients being 

upper most”. 

“Undoubtedly design teams are increasingly 

starting to work collaboratively with the offsite 

sector to specify developed solutions which will 

deliver ‘as built’ buildings which perform as 

they were specified and designed to do in the 

first place, thus closing the renowned 

performance gap of circa 20%. This is in 

addition to projects delivered on time and to 

budget”. 

“However contractors and developers seem to 

retain a very different view in too many 

instances, and see their role as being to ‘deconstruct’ 

the design solutions; to break them 

down into their individual components for 

procurement purposes ‘because it is cheaper’. 

This is entirely counter to the principles of 

offsite construction, which is all about solutions 

that ensure all the components work together, 

including the key joints and interfaces, to 

guarantee the performance of the structure. 

Who looks at a car and says right I can build 

that cheaper by sourcing all the components 

separately. It may look like the original design 

but it’s very unlikely to perform as well as the 

one sourced from the manufacturer”. 

“This was an emotional area of debate, and the 

general feeling was that construction is not 

modern enough in its thinking; it is not 

collaborating enough; there’s too much conflict; 

the answers lay in the supply chain; 

constructors need to embrace working with the 

supply chain as a real positive”. “Clearly this is 

a debate which is going to run and run”. 

Mike Stevenson is Development Director of 

offsite and new-build fenestration specialists 

Sidey and founding partner of The Fabric First 

Academy. The panel of speakers consisted of 

Darren Richards of Cogent Consulting who 

chaired the debate, Robert Clarke Fusion 

Building Solutions, Jim Roach ARV Solutions, 

John Skivington LHC, Paul Neep Architype 

Architects, Paul Wright Tremco Illbruck and Dr 

Robert Hairstans Institute for Sustainable 

Construction. 

The Fabric First Academy 

www.fabricfirstacademy.co.uk 

Sidey www.sidey.co.uk 

MEDITE VENT 

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Article > 

Value engineering – 

what’s it all about? 

As the construction industry strives to provide the optimum building solution, just how can companies today 

differentiate themselves and ensure they are offering best value? 

Lincoln gateway 

Steve Thompson, Managing Director of 

light steel frame manufacturer, EOS 

Facades explains how they are using 

value engineering and Design for Manufacture 

and Assembly (DfMA) to meet the demands of 

today’s construction industry. 

Value Engineering – What is it? 

Today’s customers are savvier, more 

commercially aware and they expect more for 

their money. As manufacturers and service 

providers, we need to react and meet this 

demand, or risk losing out. 

But before we can do this, we need to 

understand what value really is. 

Assessing best value depends on the objectives 

set - speed of construction, build costs or the 

development of a sustainable, energy efficient 

building - or perhaps a combination of all. 

Adopting a ‘one system fits all approach’ will 

not necessarily deliver best value. It is not 

about economies of scale but it is about an 

optimised approach - working with the client to 

select the right solution, at the right price, to 

deliver the right performance. 

Adding Value: Design for Manufacture and 

Assembly 

As a manufacturer of steel solutions, EOS 

Facades take full advantage of offsite 

manufacturing techniques by adhering to 

Design for Manufacture and Assembly (DfMA) 

protocols. DfMA is now recognised as the 

foundation for concurrent engineering 

processes to streamline and fully optimise the 

structure. The process aids the building design 

process and helps to identify, quantify and 

eliminate waste or inefficiency where possible. 

At EOS Facades we pride ourselves on driving 

quality through precision manufacturing whilst 

delivering accurate results on time and on 

budget. 

We have taken steps to ensure that DfMA is 

integrated throughout the design and 

manufacturing process. We have made 

considerable investment in developing 

technology to aide specification and design. We 

are totally committed to working with our 

clients on product and service innovations to 

help them gain a competitive advantage in the 

marketplace – delivering cost and time 

efficiencies. 

The EOS manufacturing facility is a 40,000 sq 

ft operation that houses state-of-the-art 

machinery and technology providing offsite 

systems and solutions that meet the needs of 

our customers. Our manufacturing facility is 

well equipped to cater for the demands of 

offsite construction and precision engineering. 

Our sophisticated roll-forming machines have 

embedded framing technology that enables 

production of self-jigging framing components 

that are ready for assembly, eliminating the 

need to manually cut onsite. 

All of our products are manufactured under 

strict quality management control which is fully 

compliant with BS EN ISO 9001:2008. Our 

accredited quality management systems and 

procedures eradicate onsite variability and 

ensure life time ‘in service’ performance and 

durability. 

Adding Value: Software and Building 

Information Modelling 

Precision built offsite products require the 

application of leading-edge technology and 

contemporary manufacturing processes. We 

have invested substantially in the latest 

software and hardware systems in steel frame 

42

production. Our systems combine the latest E- 

Frame technology platform with proven 

assembly processes, providing fully framed 

panels that do not require jigging. 

The Shard 

Sophisticated software transfers building 

design information directly to our production 

plant where we are able to manufacture to 

accuracies that exceed construction industry 

norms. Once the panels have been designed 

using our 3D Tekla modelling software, they are 

directly uploaded to the roll-forming machines, 

using a bespoke CAD/CAM interface, where 

they are produced to exact dimensions using 

CNC technology. Each stud is identified with an 

inkjet printer to match the assembly drawing 

and every frame has an identification label 

attached. This identifies the project, frame 

number, order number and site location on the 

GA site drawings so they can be positioned 

quickly to their onsite location. 

Adding Value: Product 

Product quality is essential. EOS only use 

minimum S390Nmm2 G275gsm steel (higher 

grades and coatings on request). By only using 

steel with a protective coating and design 

detailing that eliminates prolonged exposure, 

EOS are confident in the durability of our 

systems. Research has shown in these 

conditions coated steel has a potential life of 

over 1,000 years. 

The team at EOS support key industry 

standards and strive to exceed expectations on 

reliability and delivery. All of our products are 

manufactured to rigorous quality standards 

which are fully compliant with the Construction 

Products Regulations - EN 1090-1: 2009 + AL: 

2011. Our quality management systems are BS 

EN ISO 9001: 2008 registered. 

Victoria Halls London 

Adding Value: Cost 

We offer all-inclusive fixed price packages that 

are uniquely supplied with proprietary brackets 

and fixings required. All Double Studs/Opening 

Jambs/Lintels and Sills will be dispatched from 

our factory preassembled. This is a flexible 

service and should you require the product to 

arrive unassembled, EOS will pre-punch in the 

factory, ghost assemble and supply, together 

with all the necessary screws and special drill 

bits, for assembly and installation onsite. 

Adding Value: People 

EOS Facades are constantly striving to improve 

the way we work and the resulting benefits are 

passed onto our customers. Research & 

Development is a core focus of our business 

and it is not just down to one specific team, at 

EOS everybody is encouraged to put 

recommendations forward, whether this is a 

process or an alteration to a product – that way 

every part of our business can be enhanced. 

EOS also offer a total partner solution including 

application consultancy, structural design 

support and value engineering, as well as 

quality manufacturing. 

To meet the demands, we need people to make 

the change happen. 

Now the construction industry is starting to 

recognise the shift in needs of the client, 

manufacturers must ask themselves, are they 

well equipped to meet demands or will they risk 

losing out? 

For more information on EOS Facades’ products 

and services visit: www.eos-facades.co.uk 

Adding Value: Knowledge Sharing 

In a bid to share their extensive knowledge, 

EOS Facades are offering a series of CPD 

sessions, designed to highlight the various light 

gauge steel solutions available, and explain how 

these can be applied in real life scenarios. 

The hour long seminars will cover a wide range 

of steel solutions and services including: 

• Cold Formed Sections 

• SFS Infill Systems 

• SFS Onsite Stud and Track 

• SFS Offsite Pre-assembled 

• Other applications – including LBS, Lattices 

and Cassettes 

• Design 

• Partnering 

• Examples of Best Practice 

These CPD sessions could not be more 

convenient – an EOS Facades technical 

representative will come directly to you and the 

seminars are completely free of charge. Get 

involved and start talking about light gauge 

steel! 

To request your CPD session, simply contact 

Thomas Elliott, EOS Facades Technical Sales 

Manager on thomas@eosuk.org or 

07528 364 581. 

www.eos-facades.co.uk 


Article > 

Medite & Smartply set sights 

on off-site construction 

Wood panels are the natural choice for developers and house builders looking to utilise the time, cost and quality benefits of offsite 

construction. In particular, engineered wood panels offer specifiers, timber frame manufacturers and contractors the 

enhanced flexibility, improved quality and superior safety to ensure the industry continues to build for the future. 

Leading manufacturers of engineered 

wood panels, Medite and SmartPly offer a 

wide range of high performance products 

for wall, floor and roof applications. From the 

breathable Medite Vent to the new SmartPly 

VapAirTight with integrated vapour control and 

air barrier properties – Medite and SmartPly 

provide high performance, environmentally 

friendly and easy to install products that are 

perfect for modern construction. 

Lessons in performance 

At the University of East Anglia’s (UEA) 

landmark development The Enterprise Centre, 

over 11,000m2 of SmartPly OSB3 was supplied 

for use in the structural timber frame. 

Manufactured using zero added formaldehyde, 

SmartPly OSB3 met the client and contractor’s 

strict requirements for proven performance 

and extremely low environmental impact. 

The build-up of the wall panels featured 18mm 

taped SmartPly OSB3 on the inside for racking 

and airtightness, followed by a 140mm cellulose 

insulated structural stud, a thermal break 

cavity filled with cellulose insulation and a 

second 63mm insulated stud. 

For projects where flame retardance is a 

prerequisite, SmartPly has developed SmartPly 

FR OSB3. Manufactured using Zeroignition 

Solution, a water based, eco-friendly, fire 

retardant, this penetrates into the wood 

strands to ensure best in class fire performance 

whilst fully maintaining structural integrity. 

At the construction of The Edge – a sevenstorey, 

timber frame accommodation building 

for students of John Moores University and 

University of Liverpool – SmartPly FR OSB3 was 

specified over conventional post-treated wood 

panels due to its guaranteed consistency and 

excellent flame retardant properties. 

The future of OSB 

Environmental credentials are now a crucial 

requirement in modern construction. With 

Passivhaus and low energy construction 

growing in popularity, SmartPly developed a 

structural panel that meets these requirements. 

The new SmartPly VapAirTight OSB panel, for 

which a patent is pending, is specifically 

engineered to deliver outstanding levels of 

airtightness and vapour control. 

Each panel features alternating layers of wood 

strands coated with a high quality 

formaldehyde-free resin and wax binder system 

to deliver outstanding levels of airtightness. A 

specialist coating is then applied to ensure 

vapour resistance and provide a premium 

performance OSB solution for super-insulated 

and passive buildings and enabling the 

elimination of a traditional additional vapour 

control membrane. 

Breathe more easily 

When designing and building timber frame 

structures, the risk of interstitial condensation 

is a key consideration as it can lead to mould 

growth, health issues and can even compromise 

structural integrity. Medite Vent meets the 

need for a breathable panel for use in external 

sheathing for all types of timber frame 

construction, supporting a well-ventilated 

building design. 

Combining high racking strength in excess of 

Category 1 requirements with excellent vapour 

permeability and high weather resistance, 

Medite Vent is an ideal choice for the outer 

layer in ‘diffusion open’ wall and roofing 

applications. Medite Vent is also produced 

using zero-added formaldehyde and carries the 

CE mark in accordance with EN 13986 – making 

it a sustainable, reliable and high performance 

choice for low energy construction projects. 

Engineered wood panels deliver quality, 

performance and durability for a wide range of 

structural and non-structural applications. The 

specialist ranges of high performance and 

environmentally friendly systems from 

SmartPly OSB and Medite MDF make them the 

natural choice for forward-thinking architects, 

specifiers and contractors. 

www.coilltepanelproducts.com 

44

Celotex launches concrete soffit liner insulation solution 

Insulation specialist Celotex has once 

again demonstrated its innovative 

credentials with the launch of Celotex 

SL5000. Specifically targeted at 

concrete soffit liner applications, 

Celotex SL5000 is an exciting new 

addition to the company’s ‘5000’ 

series premium performing product 

range. 

Designed for concrete soffit liner 

applications, Celotex SL5000 is a 

premium performance thermal 

insulation board combining premium 

performance PIR insulation bonded to 

6mm calcium silicate, providing 

additional fire performance. With a 

super low lambda value of 0.021W/mK, 

SL5000 ensures Regulatory 

compliance is achieved with minimal 

insulation thickness. 

Celotex SL5000 provides on-site 

benefits too, significantly reducing 

installation times due to the insulation 

and calcium silicate being supplied as 

one product. Delivering greater impact 

resistance compared to exposed 

insulation systems, SL5000 provides a decorative finish with no need for on-site decorating. 

“As an innovator within the insulation sector, we are always looking to develop solutions for the most challenging applications,” said Paul 

Evans, Head of Marketing at Celotex. “Celotex SL5000 further enhances our range of solutions and achieves Building Regulation targets with 

thinner solutions than many other insulation materials.” 

Offering excellent sustainable qualities, the insulation component of SL5000 is A+ rated when compared to the BRE Green Guide and Class O 

fire rated. 

Available in thicknesses from 86mm to 106mm and a board size of 1200mm x 2400mm, Celotex SL5000 can be installed by direct fixing to 

the concrete soffit or by indirect fixing via treated timber battens. The Celotex Technical Centre are on hand to answer and technical queries 

for existing or future projects. Visit celotex.co.uk for contact information. 

Celotex has a long and proud history of continuing to develop new and innovative solutions. With a clear focus on maximising thermal 

efficiency with thinner solutions, the new Celotex SL5000, gives specifiers a solution for concrete soffit liner applications. 

Knauf Spray Plaster keeps boutique motel to tight schedule 

www.celotex.co.uk 

Ready Mixed Spray Plaster developed by Knauf delivered the finest finishes on the 

fast-track construction programme to develop a major new hotel in the centre of 

London - Motel One London-Tower Hill. 

“The major advantage with these products is the speed at which you can apply them 

– three or four times faster than manual application,” said Matt Smith, who runs the 

specialist subcontractor Spray Plastering Specialists appointed by McAleer & Rushe. 

“We have far greater control because there are fewer people on site. We have a team 

of just three people and we can do 30 rooms a week. We have one guy working ahead 

of us filling and jointing and two people spraying plaster,” he said. 

Knauf’s range of Ready Mixed Spray Plasters enable up to 1,000m2 per week can be 

finished by a three man gang, while surfaces can be emulsioned within 24 to 48 

hours, so the plaster can be applied by the same teams applying the paint finishes. 

They offer a range of finishes, including flat and smooth, textured, leathered, combed 

or rollered. 

www.knauf.co.uk 



First Street in 

Manchester gets a 

Home 

Prater has recently delivered the 

external cladding and roofing works at 

independent film hub and visual arts 

centre, Home, in First Street, 

Manchester. Completed in April 2015, 

Home forms part of a 20 acre 

development in the heart of 

Manchester city centre. 

Performing for zero carbon timber homes 

An example of how timber is playing a major role in the UK’s first eco-town NW Bicester is a 

collaboration between Stewart Milne Timber Systems and the A. Proctor Group, which is 

providing high thermal performance using off-site modules. The first phase of A2Dominion’s 

development in the new town is a project to deliver 393 homes with a ‘true zero carbon’ 

rating and offering energy efficient, good quality, affordable housing. 

The A. Proctor Group has supplied its Roofshield and Reflectashield TF 0.81 membranes for 

pre-assembled modules. These pre-assembled elements enable a pair of semi-detached 

homes to be weathertight, secure and fully insulated within 72 hours. 

Roofshield is an air and vapour permeable roofing 

underlay which provides a high degree of water 

resistance; the product provides the most costeffective 

solution to controlling interstitial 

condensation in a pitched roof. Reflectashield TF 0.81 is 

a vapour permeable low emissivity membrane for use 

externally on timber frame buildings. 

www.proctorgroup.com 

Making light work of brick soffits 

Creating flawless brick-faced soffits and lintels has 

now become much simpler and quicker, thanks to a 

new lightweight stainless steel-based system 

developed by two industry-leading companies - 

brick support specialist Ancon Building Products 

and Ibstock Kevington – national manufacturer of 

brickwork and masonry special shapes and 

prefabricated components. 

The new Nexus® system combines a specially 

developed Ibstock Kevington lightweight brick-faced 

steel unit with Ancon’s tried and tested MDC 

stainless steel bracket angle support system. The system offers contractors easier handling 

coupled with maximum adjustability, both vertically and horizontally, for quick and simple 

alignment on site. 

Working to a tight deadline, the 

specialist contractor’s experience and 

proven capability on complex projects 

was crucial. Furthermore, Prater’s inhouse 

design team made an invaluable 

contribution to the project overall, and 

the ability to utilise off-site fabrication 

at one of Prater’s factories helped to 

overcome significant logistical 

challenges on-site. 

Prater was appointed by main 

contractor Wates in a contract worth 

£2.5m to deliver the roofing and 

cladding package for Home. Overall, 

Prater was responsible for installing 

over 51 units of Reynaers Curtain- 

Walling, a range of Reynaers CS68 

Doors and Hortons 2001 Sliding Door 

units, as well as 826 Trimo Rainscreen 

Composite Panels and Radmat’s 

Permaquik hot melt waterproofing 

system for the roofing works. 

www.prater.co.uk 

The new system offers considerable benefits over traditional cast concrete alternatives – 

cutting weight by more than half, which in most cases will allow the brick-faced units to be 

installed without specialist lifting equipment, and significant savings in installation time – 

making it particularly appropriate for fast-track or time-limited projects. 

Rebrand transforms Roan to Actavo 

www.ancon.co.uk/Nexus 

Roan Building Solutions has been transformed into Actavo as part of Siteserv’s rebranding of 

all its companies including EventServ, Deborah Services and Sierra Support Services, to come 

together as one unified team. 

Operating globally in over 100 locations, the move to Actavo comes against the backdrop of a 

number of large-scale contract wins internationally. The change sees a transformation from 

being a holding company with autonomously operating entities in to one company with 

actively-managed, inter-related business solutions. 

Welcoming the rebrand, CEO of Actavo Structural Division, Roger Hastie, said: “Actavo will 

continue to deliver the quality goods, services and expertise we provided as EventServ, for 

example. In addition to this, we will be offering customers greater choice and access to the 

capabilities of the entire Actavo Group.” 

Commenting on the rebrand name, Vivienne Walshe, marketing director at Actavo, said: “The 

inspiration for the name Actavo comes from Actus, the Latin word for performance. Actavo 

reflects our dedication to performance, to energy and to our active spirit in pursuit of 

excellence. Furthermore, it is a call to action to our entire workforce of 4,500+ employees, 

incentivising everyone to find new ways to work better, reach higher, go further, prosper and 

enable our customers to grow.” 

www.actavo.com. 

46

Bu 

ilding Board 

Systems fro om your 

sol utions-fo cused 

con nstruction n partner 

SHEATHING 

FI 

RE 

ACOUSTICS 

Cement Particle Sheathing Board 

Class ‘0’ reaction to fire 

BS 476 part 22 Fire Te ested Systems 

CE marked according to EN 13986 

E N 594 Racking Test 

for 

Walls 

Cement Particle Sheathing Board 


BS 476 part 22 Fire Te ested Systems 

CE marked according to EN 13986 

E N 594 Racking Test 

F SC Chain of Custody Certificationtion 

fo or Walls 

RE ENDER BOARDS 

F ire and Acoustic Floor System 


E N 1195 tested 

fo or Floors 

PA 

ARTITIONS 

WALLS 

FLOORS 

ROOFS 

F ire and Acoustic Lining Board / 

Rainscreen Carrier 

A1 non-combustible reaction to fire to 

E N 13501-1 EN 12467 

Helps gain compliance with BR 135 

E N 594 Racking Te est 

fo or Walls 

F ire Protection Board 

A1 non-combustible reaction to fire to 

E N 13501-1 EN 12467 EN 1364-1 & 

E N 1365-1 tested systems 

fo or Partitions and Walls 

Direct Render Base Board 

Class ‘0’ reaction to fire EN 12467 

BBA certified systems 

Compatible with a wide range of 

le 

eading manufacturers’ base coats 

fo or Walls and Soffits 

Contact our technical/sales team for a quotation 

01925 860999 

www.euroform.co.uk 

info@euroform.co.uk 

FSC ® C084663 

This advert i s a general guide and specific technical advice 

is recommended before proceeding wi th any 

transaction. F ull technical information available on 01925 860999.

MMC 5541 48 Nov'15 cc

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