a.aa MMC M11 52pp Web

MMC 

MODERN METHODS 

OF CONSTRUCTION 

// Feb 2019 

// Kingspan TEK System incorporating 

A. Proctor Group’s Wraptite 

External Air Barrier 

CSM (UK) Ltd develops 

the solution… 

CSM has developed the 

solution for fire compliant 

concrete sandwich panels. 

Tech giants investing 

in offsite 

How tech giants are beginning 

to invest heavily in offsite 

throughout the World. 

How modular approaches 

are transforming… 

Why 2018 felt like a 

breakthrough year for 

offsite construction. 

Change is in the air 

Fire Doors and related risk 

critical products are playing 

an ever more significant role 

in safety. 

P 6 P 12 P 28 P 44

Rapidr es is an innovative offsite fsite fastrack modular 

precast concrete build system, delivering i robust 

 

 

 

 

 

programme savings. 

It is ideally suited to multi-storey projects such as: 

• Apartments 

• Student accommodation 

• Hotels 

• Social housing 

• Custodial 

INNOVATION 

IN CONCRETE 

Tel: 028 7965 0500 

info@creaghconcrete.com 

www.creaghconcrete.co.uk

Feb 2019 

issue M11 

The construction sector is vital 

to both the UK economy and to 

the Government, if we are to 

achieve our economic and 

social ambitions. But, to make 

the most of the opportunities 

available, the sector needs to 

modernise quickly. We need to 

make the most of the skills and 

expertise that already exist in 

the sector throughout the UK 

and, in turn, create a major new 

export opportunity for our post- 

Brexit economy. The only way to 

do this is by undertaking in a 

fundamental shift towards 

offsite construction methods. 

Research suggests that just 7% 

of UK construction is currently 

undertaken in this way. By 

increasing this proportion to 

25%, productivity in the sector 

could increase by 3.6% by 

2020. The long-term economic 

benefits to the whole of the UK 

are even larger. 

With this in mind, MMC Feb 

issue brings together the latest 

news, views, case studies and 

comments from offsite industry 

leaders, providing you with all of 

the information necessary to 

help spark the next industrial 

revolution. The future is 

modular. Be part of it. 

Joe Bradbury 

Editor 

MMC 

MODERN METHODS 

OF CONSTRUCTION 

14 Connex Offsite a company with big ideas 

Connex Offsite is a bathroom pod manufacturer based in a brand new 

factory in Newry, Northern Ireland and is part of a larger group of 

companies specialising in Construction, Engineering, Waste Management 

and Robotics. 

22 New & improved EZWall launched 

Construction material specialist, Euroform, is continuing to widen the 

variety of finishes available in its already popular EZWall cladding system 

range, which cleverly combines the advantages of modern construction 

techniques with the appeal of traditional brickwork. 

36 The Evolution of MMC 

After the Second World War the UK saw a rapid demand for house 

building and solutions needed to be provided quickly and efficiently. Sixty 

years on and modern methods of construction (MMC) has seen a 

staggering evolution and investment. 

42 A ‘modular mindset’ is needed to tackle 

London’s housing crisis 

London needs 66,000 new homes each year. However, in recent history, 

nothing like this capacity has ever been delivered. In 2016-17, there were 

just 41,371 net additions to London housing stock. Less than 5,500 

affordable homes were completed in 2017-18. 

46 SE Controls creates dedicated 

smokecontrol solution for newcastle USB 

Front cover 

For modular buildings to be energy 

efficient, healthy, and moisture free 

what is required is a holistic 

approach to a total system which 

manages the balance of Heat, Air, 

Moisture Movement (HAMM), 

considering an integrated approach 

to airtightness, insulation and 

condensation control. 

For more information see page 32 

Publisher Kevin Edgeworth 

Editor Joe Bradbury 

Designer Ellie Rich 

Newcastle University’s innovative and multi-award winning Urban 

Sciences Building (USB) is using a combined smoke control and 

environmental ventilation solution that incorporates a SHEVTEC control 

system, which was engineered by SE Controls to meet the unique 

requirements of the project. 

Sales and editorial enquiries to Kevin Edgeworth 

kedge@wavcoms.co.uk | 0121 661 6860/07771 500333 

Press releases to Gemma Spilsbury press@mmcmag.co.uk 

Publisher’s Statement. Printed in England. All rights reserved. No part of MMC may be reproduced or stored in a retrieval system or transmitted in any form without 

prior permission of the publisher. Whilst every effort is made to ensure the accuracy of editorial content, the editor and publishers do not accept responsibility for 

errors or loss and damage caused by any statements, claims or observations made by contributors, authors and their agents. 

Published by Waverley. Company Registration no. 04805329 

Feb 2019 M11 3

news 

UK housing market faces challenging 2019, warn experts 

The UK housing market is unlikely to see much change in 2019 with a continuation of weakening sales activity, according to the RICS UK 

Residential Housing Forecast 2019. The UK housing market has lacked impetus in 2018, having continued to struggle with a lack of homes on 

estate agents books; affordability issues; uncertainty caused by Brexit; and prospective interest rate rises. 

Looking ahead, it is unlikely that sales will grow in 2019. In the past two years, sales activity has declined, and annual completed transactions remain 

significantly below the 1.7million high reached in 2006. Given the obstacles in the current market it is anticipated that activity will weaken further. 

As sales activity continues to falter, house price growth will continue to fade in the first half of the year and is expected to come to a standstill by 

mid-2019. As such, the RICS Housing Forecast 2019 suggests prices will neither grow nor fall in the near future (0%). 

The stagnation of house prices is underpinned by the lack of new properties being listed for sale. In the second-hand market, not enough properties 

have been listed to replenish those sold. This has been evident in the RICS data throughout 2018, as average stock levels remain near all-time 

record lows. The number of new properties being listed for sale has fallen consistently, and in November, almost half of survey participants reported 

the number of market appraisals undertaken over the month was down on the year before. All these indicators suggest it is unlikely that the coming 

months will see a marked increase in supply across the second-hand market. 

Saint-Gobain acquires SIG 

Roofspace to deliver more 

off-site manufactured 

solutions for housebuilders 

Saint-Gobain UK & Ireland completed the acquisition of SIG 

Roofspace Solutions on the 14th December 2018. 

The business, set-up in 2008 provides a turn-key panelised roofing 

and room-in-roof solution to house builders. 

Mike Chaldecott, Saint-Gobain UK & Ireland CEO said "We're delighted 

to welcome Roofspace to Saint-Gobain. They are a great business that 

provides solutions to customers that saves them time and streamlines 

the construction process. We know that the construction industry has 

to be more efficient, more productive, more innovative and embrace 

off-site manufacturing. Roofspace are already offering customers 

these benefits and have delivered roofs for over 2,500 new build 

homes in the last year". 

"Roofspace further accelerates our capability to serve the rapidly 

expanding off-site manufacturing sector adding to our expertise which 

already includes our Pasquill business, and their timber roof-trusses, 

Scotframe's timber-frame houses and Saint-Gobain steel-frame 

systems". 

SIG Roofspace Solutions will now be known as Roofspace. 

Slower rise in commercial 

work weighs on construction 

growth at the end of 2018 

UK construction firms indicated a disappointing end to 2018 as 

business activity growth eased to a three-month low and new orders 

expanded at a relatively subdued pace. The main bright spot was a 

sustained rebound in civil engineering activity, which rose at the 

fastest pace since May 2017. 

Business optimism also picked up in December. The degree of 

confidence was the highest since last April and well above the near 

six-year low seen in October. Survey respondents cited hopes of a 

boost to growth from work on big-ticket transport and energy 

infrastructure projects in 2019. 

At 52.8 in December, down from 53.4 in November, the headline 

seasonally adjusted HIS Markit/CIPS UK Construction Total Activity 

Index posted above the crucial 50.0 no-change value for the ninth 

consecutive month. 

Anecdotal evidence suggested that subdued demand conditions 

were the main factor behind softer output growth in December. 

There were also some reports that unusually wet weather had acted 

as a brake on construction work. 

Intelligent systems will help UK transition to clean and 

affordable energy 

New small-scale renewable electricity providers to be guaranteed payment for excess electricity supplied to the grid under new government 

proposals – protecting consumers from unfair costs associated with current scheme. Plans for Smart Export Guarantee could build a bridge to the 

smarter energy system of the future, which can help unlock technological innovations like home energy storage and more efficient electric vehicle 

charging. Households and businesses installing new solar panels will be guaranteed payment for power provided back to the grid under government 

proposals set out this week to unlock the smart energy systems of the future- an important upgrade to the current Feed-in Tariffs scheme. 

The proposed ‘Smart Export Guarantee’ (SEG) would replace the existing ‘Feed-in Tariff’ scheme (FIT), with electricity suppliers paying new small-scale 

energy producers for excess electricity from homes and businesses being put back into the energy grid. The new scheme could create a whole new 

market, encouraging suppliers to competitively bid for this electricity, giving exporters the best market price while providing the local grid with more 

clean, green energy, unlocking greater choice and control for solar households over buying and selling their electricity. 

4 

Feb 2019 M11

London overtaken by rest of Britain in housebuilding growth 

London’s homebuilders have been outpaced by the rest of Great Britain as investment in housebuilding dropped to its lowest value in six years. 

Residential contracts awarded in London in 2017 were 34% lower than the value awarded in 2016, which is in contrast to the majority of regions 

outside of the capital that experienced growth. 

Although London is the largest regional GB economy, and had £3.6 billion of residential contracts awarded in 2017, an increase in demand for new 

homes is coming from areas such as Manchester, Birmingham, and Sheffield as they undergo city centre regeneration projects. Across all GB 

regions, London came bottom for residential contracts growth, with overall values falling by 33.9% from 2016 to 2017. 

Rebecca Larkin, Construction Products Association Senior Economist said “London has slipped from its position as a residential star performer as 

the slowdown in inner and outer London housing markets appears to have cooled developer confidence. House prices in the capital have been 

falling since the middle of 2017, but this is unlikely to ease affordability constraints. The average London house price is more than double that in 

the North West, West Midlands and Yorkshire & Humber, and combined with stronger uptake of Help to Buy in these regions, is helping to 

underpin regional housing demand.” 

Inner-city building sites can 

be an oasis of peace and 

tranquillity 

Volumetric Modular in-fill city homes are fast to install with minimum 

of noise and disruption to the surrounding area. 

Building sites are usually noisy, dirty and very disruptive to the 

community in which they are located, so neighbours rarely welcome 

them even when new housing is desperately needed. But it does not 

have to be like that as Brian Maunder of pioneering construction 

company Totally Modular Ltd explains: 

“Volumetric construction is a technique in which houses are built 

off-site and delivered as complete ready to go modules. They are 

craned onto prepared foundations and connected to the utilities. In a 

matter of hours, they are ready for occupation. 

“As well as houses, blocks of flats can be built in exactly the same 

way, with each flat being a module that can be stacked and arranged 

in almost any configuration up to 11 storeys high (although currently 

most projects are low rise). This is possible because all units are built 

around an incredibly strong three-dimensional steel frame. 

Modular village to be built in 

Corby for London commuters 

Groundworks have started on a new modular village in Corby, 

Northants targeted at London commuters. 

The 47 homes will be built at Priors Hall Park by modular specialist 

Project Etopia who took over the site when a previous eco-homes 

scheme stalled. 

Etopia Corby will contain 31 houses and 16 apartments with a 4-bed 

expected to sell for between £320,000 and £350,000. 

Factory construction of exterior shells of the new homes will start in 

February and the first four homes are due to be completed by the end 

of March with each unit taking no more than six to eight weeks to build. 

Joseph Daniels, CEO of Project Etopia, said "Corby is leading the way in 

showing how villages of the future should be built. Modular building is 

now so advanced, it is senseless to cling to bricks and mortar, which 

takes longer to build and is far more expensive. 

"Commuter villages like this offer younger would-be homeowners the 

wage benefits of working in the capital but without the high property 

costs, and Etopia Corby will be a model other councils can follow." 

Construction output rises despite Brexit uncertainty 

The Government must not be complacent about the damage a ‘no deal’ Brexit would cause amid positive signs of growth in the UK construction 

industry, says the Federation of Master Builders (FMB). 

Commenting on recent construction output figures published by the Office for National Statistics, Sarah McMonagle, Director of External Affairs at 

the FMB, said “The UK construction sector grew by 2.1 per cent during September to November 2018 compared with the previous three months. 

This is despite unparalleled levels of political uncertainty around the very real prospect of a ‘no deal’ scenario. However, we are urging the 

Government not to allow these results to create a false sense of security. Since November, political uncertainty has cranked up and is increasing 

every day. A growing and prosperous construction sector will be a distant memory if the Government allows the UK to crash out of the EU without 

a deal in place.” 

DfE shares plans for £2bn offsite schools framework 

The government's Department for Education is planning an industry meeting to discuss its plans for a £2bn offsite schools framework. 

The Department for Education (DfE) plans to set up a four-year framework for the delivery of schools by design for manufacture and assembly 

and/or offsite methods. It will follow on from the DfE's existing component school frameworks and supplement the existing DfE construction 

framework. The DfE anticipates, subject to consultation, that any new framework will be larger than the previous frameworks with a target to 

deliver up to a 100 new school projects a year by 2023. 

It will be based on a greater degree of standardisation and focused on a manufactured offsite solution, to improve quality and efficiency to deliver 

programme and value savings. 

It will also be open to a greater number of suppliers and different methods of offsite construction, including modular and portable buildings, kit 

buildings and prefabricated componentry. 

Feb 2019 M11 

5

article 

CSM (UK) Ltd Develops 

the Solution for Fire 

Compliant Concrete 

Sandwich Panels 

Apartments, Birmingham 

In response to new UK Government building regulations, CSM (UK) Ltd has developed the solution for fire compliant concrete sandwich 

panels using Thermomass® and mineral wool insulation. 

Non-Combustible Core 

For 20 years, CSM (UK) Ltd has helped 

customers in the UK and Ireland design 

and build concrete sandwich walls using 

the Thermomass® system. Over this period, 

there has been a sizeable growth in the use of 

Thermomass® concrete sandwich panels by the 

pre-cast concrete industry, caused notably by 

the increase in architecturally designed 

structures in concrete across multiple sectors, 

assisted by the speed of construction, certainty 

of cost and programme and a drive to achieve 

the greater energy efficiency that Thermomass® 

provides. 

Following the fire at Grenfell Tower on 14 June 

2017, the UK Government decided to act and 

ensure future high-rise projects built in England 

were fire safe. As of 21 December 2018, The 

Building (Amendment) Regulations 2018 came 

into action, whereby the UK Government has 

banned combustible materials within external 

walls on new high-rise buildings in England. 

According to the regulation, relevant buildings 

must be above 18 metres tall and contain 

dwellings, an institution or a room for residential 

purposes, excluding rooms in “a hostel, hotel or 

boarding house”, stating that all construction 

elements within should be classified with an A2- 

s1, d0 or A1 European Fire Classification, the 

highest rating possible. 

Such an amendment could have immediately 

posed a threat to the concrete sandwich panel 

industry who, at present, rely on thermal 

insulations such as Polyisocyanurate (PIR), 

Graphite Expanded Polystyrene or Phenolic 

insulations, all of which all fall short of the 

European Fire Classifications required. 

However, considering these new regulations and 

risks, CSM (UK) Ltd, supplier of the Thermomass® 

System in the UK and Ireland, has collaborated 

with mineral wool insulation manufacturers, to 

supply to the pre-cast industry with the solution 

to achieve an A1 European Fire Classification in 

concrete sandwich panels, for exclusive use as 

the thermal insulation in Thermomass® concrete 

sandwich panels. 

Thermomass® is the market leading fixing for 

concrete sandwich panels, having supplied more 

than 80 million m2 worldwide without a single 

failure. Customers choose Thermomass® for 

many reasons, notably because all panels are 

thermally broken, delivering 100% thermally 

efficient insulation which eliminates interstitial 

and surface condensation, no projects require 

scaffolding and all panels have superior acoustic 

and fire properties, including a four-hour fire 

resistance when tested in accordance with BS 

EN 1364-1: 1999. 

The solution CSM (UK) Ltd has developed with 

mineral wool manufacturers is a non- 

Hotel, Manchester 

6 


…Thermomass®panels 

are thermally broken, 

delivering 100% 

thermally efficient 

insulation which 

eliminates interstitial 

and surface 

condensation, no 

projects require 

scaffolding and all 

panels have superior 

acoustic and fire 

properties, including 

a four-hour fire 

resistance… 

Steel Concrete Thermomass 

combustible stone wool insulation made 

specifically for concrete sandwich panels. This 

insulation is made from molten mineral stone, a 

renewable and plentiful naturally occurring 

resource, providing panels with not only the 

benefits of Thermomass®, but also the 

compression resistance required for concrete 

pouring, increased vapour resistance to ensure a 

low U Value panel and, most importantly, an A1 

European Fire Classification. 

CSM (UK) Ltd are considered by our customers 

not as suppliers, but partners in their business, 

ensuring an unparalleled quality of service and 

expertise in the concrete sandwich panel 

industry. Following the new regulations coming 

into force we acted fast to ensure our customers 

could continue to succeed. Now, we can supply 

them with a cost-effective regulation compliant 

solution, specifically designed for the 

Thermomass® System, to continue to exceed 

their expectations for durability, energy-efficiency 

and award winning attractive building designs. 

For more information, please call 

+44 (0)1246 853528, email sales@csm-uk.co.uk 

or visit the below website. 

www.csm-uk.co.uk 

Test Panel 

Student accommodation, Birmingham 

7

product news 

Klober Permo ® air gets public sector 

performance recognition 

Klober has received a significant boost for its market-leading low resistance 

air-open underlay Permo® air with certification by Local Authority Building 

Control (LABC) for its Registered Details scheme. 

Designed to meet this requirement and prevent condensation forming in 

the roofspace, Klober Permo® air offers an exceptional level of breathability. 

It has a water vapour transmission sd-Value of 0.009m and a water vapour 

resistance confirmed to be as low as 0.045 MNs/g. As a result, it has been 

specified for roofing upgrades of many high profile and historic buildings. 

For new builds, particularly those with complex roof designs, underlay 

performance is put under greatest strain during the critical drying out 

period. Permo® air’s use on both cold and warm roof installations avoids the 

additional cost of supporting ventilation and offers the additional benefit of 

having been tested for wind uplift resistance by the BRE. 

BBA and IAB approved, Permo® air not only avoids the additional cost of 

supporting ventilation, but also interruptions in the roofline caused by 

traditional tile or slate vents. Being manufactured from polypropylene, it is 

also fully recyclable. 

www.klober.co.uk/shop/category/air-open-underlay 

New protective adjustable threshold 

Yeovil-based 

Cavity Trays Ltd 

has developed a 

ready-to-use 

solution to 

eliminate a 

reoccurring 

construction 

problem when 

building on 

contaminated 

land. Originally 

conceived for 

Radon gas situations, it is called the Type PAT - Protective Adjustable 

Threshold. 

Using flexible DPC requires support from higher courses and creates 

a cumbersome arrangement in which achieving a gas and water-tight 

arrangement that links with threshold and closers is difficult. 

The Type PAT eliminates this problem. 

The new Protective Adjustable Threshold (Type PAT) from Cavity Trays 

provides both gas and water protection under and to the sides of 

every opening and does so in a way that eliminates discontinuity and 

provides adjustable connection with adjacent barriers. 

The Type PAT – Protective Adjustable Threshold – is a threedimensional 

DPC unit that is bedded within the external wall opening. 

Integration between wall barriers and the Type PAT is achieved using 

the adjustable side connectors that attach to the Type PAT and slide 

up and down to the requisite level. 

www.cavitytrays.com 

Glasdon is ‘in its Element’ with latest 

GRP housing 

The high quality, 

cost-effective 

Element 

housing range 

incorporates 

corrosion, 

vandal and 

weather 

resistant 

modular GRP 

panels for 

ultimate 

flexibility. 

Customisation 

is available with 

a choice of 

optional fittings: 

door stays, vent 

and gland plates, and a range of locking systems. 

Delivered fully assembled, Element can quickly be put to use. Typical 

applications include: electrical and switchgear enclosure, transformer 

housing, control room or generator housing. 

With 50 years of Buildings and Housing experience, Glasdon is 

renowned for quality, design and cost-effectiveness. View Element at 

uk.glasdon.com/Element or talk to the Glasdon team (01253)600410. 

uk.glasdon.com 

Offsite Solutions wins second Manufacturer 

of the Year Award 

Offsite Solutions has 

reaffirmed its position as 

the UK’s leading bathroom 

pod manufacturer, with its 

second Manufacturer of 

the Year Award. 

This latest award was 

presented at the Business 

Leader Awards and follows 

the Manufacturer of the 

Year Award which Offsite 

Solutions won at the Made 

in the South West Awards last year. The company was also a finalist in the 

Made in the UK Awards. 

Over 200 entries were received for this year’s Business Leader awards – a 

record number. The judges commented that the calibre of entries for 2018 

was ‘incredibly high’. The awards event was attended by over 600 guests 

which included business leaders, celebrities, VIPs and professionals. 

Commenting on this latest accolade, Richard Tonkinson, Executive Director 

of Offsite Solutions said, “We are all delighted to receive this brilliant 

accolade for our business. The award is well deserved recognition for the 

dedication, hard work and talent of everyone involved in manufacturing our 

industry-leading products and for making our business the success it is 

today.” 

“We are proud to be leading the market in UK bathroom pod manufacture 

and to be helping developers and contractors across the country to 

radically improve the speed, quality and efficiency of bathroom 

construction.” 

www.offsitesolutions.com 

08 


minutes not days. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13/4974 

CREAGH CONCRETE PRODUCTS LTD 

Email: spantherm@creaghconcrete.com 

www.Creaghconcrete.co.uk/spantherm.html

article 

Chris Holleron 

ENSURING 

HIGH-QUALITY 

OFFSITE HOMES 

Modular unit built from Hadley Steel Framing being 

lifted into position at Edgeware Road project 

Modern methods of construction could help the UK overcome its housing crisis but only if the necessary standards around quality are in 

place. In this feature, Chris Holleron, Group Product Manager – Housing at Hadley Group, details how the industry can ensure this is the case 

In the past decade, the built environment 

sector has looked to embrace more modern 

methods of construction, paving the way for 

more efficient future building practices. The 

change couldn’t come at a better time, with the 

UK struggling to build enough homes to support 

its ever-growing population. As a result, both the 

Government and housebuilders are looking to 

further invest into these methods and boost 

supply. 

Much of the momentum behind this shift can be 

traced back to the Farmer Review, which was first 

published in 2016. At the time, nobody could have 

predicted the report’s impact. The hard-hitting 

document, entitled ‘Modernise or Die’ was highly 

critical of practices within the sector and 

challenged the industry to improve. One of the 

proposed solutions was for the further adoption of 

offsite construction techniques. In the intervening 

years this has certainly been the case, with major 

housebuilders investing in offsite construction 

practices. In fact, even the Government’s housing 

agency, Homes England has built its new southeast 

office using offsite techniques. 

The benefits of offsite construction 

The offsite building process is by nature repetitive, 

which means those who are performing it can 

perfect the required techniques over time. This 

helps developers to ensure a project can be 

delivered on time. 

Additionally, building offsite reduces the overall 

work required to complete a project. Studies have 

shown that far less labour is required to construct 

a building in a factory setting. In fact, The Steel 

Construction Institute (SCI) has claimed that the 

amount of work required could be reduced by as 

much as 75 per cent on a four-storey residential 

development. 

Rebuilding the housing supply 

These benefits could prove to have a significant 

impact for the UK housing industry, which 

desperately needs to build more homes in the next 

few years. Recent research by Heriot-Watt 

University says England has a backlog of 3.91 

million homes, meaning 340,000 new homes 

need to be built each year until 2031. This number 

exceeds even the Government’s target of 

300,000 additional homes per year. To achieve 

this goal, the Treasury has announced that it will 

favour offsite manufacturing on all publicly funded 

construction projects from 2019. 

Balfour Beatty, one of the UK’s leading 

infrastructure groups has committed itself to 25% 

use of offsite construction methods by 2025. This 

intense investment into the technologies has a 

number of benefits for the broader construction 

industry, however it must be managed carefully so 

that the industry doesn’t overextend itself and 

deliver low-quality homes. 

Delivering high-quality homes 

To ensure that offsite homes are delivered to a 

high-quality, a number of industry bodies are 

looking to bring a comprehensive set of building 

regulations to market. One of those standards, 

BPS 7014 has been established by the BRE 

Group to test offsite development projects in terms 

of structural, fire and acoustic performance. 

Likewise, the BSI Group is examining whether 

additional standards may be necessary for the 

sector. Together the public bodies are analysing 

the offsite sector to look for gaps in coverage and 

whether additional standards are necessary. 

As a manufacturer in the offsite construction 

supply-chain, Hadley Group welcomes these 

impending standards and hope they will help to 

further encourage the use of modern methods of 

construction throughout the country. Hadley 

Group’s light gauge steel profiles for the use in 

offsite contruction have been developed from 

years of in-house research and development. As a 

result, they will perform to exceptionally high 

standards, which will ensure that they meet any 

requirements set out by the relevant trade bodies. 

It’s essential that the industry works together to 

ensure the same high standards are met across 

the board, especially given that this remains a 

relatively new concept comparative to traditional 

methods and still needs to win buy-in from the 

broader public. 

www.hadleygroup.com 

Hadley Steel Framing 

in-situ at a project on 

Edgeware Road 

10 Feb 2019 M11

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article 

Tech giants investing in offsite 

Offsite construction offers a wealth of benefits to all who utilise it within their project. It can halve build time, encourage a 95% recycling 

rate, provide an 80% reduction in waste, and result in a higher quality of building due to tighter controls imposed on the factory floor. 

All of the signs and signals suggest that 

this is the direction we are heading in as 

an industry. The World is poised on the 

brink of a modular revolution, with industry 

experts predicting that 30-40% of construction 

in Britain alone will be built offsite within the 

decade. 

It comes as no surprise then to see tech giants 

beginning to invest heavily in offsite throughout 

the World. It was only a matter of time. Let’s take a 

look: 

Amazon 

Online retailer Amazon (the 18th largest company 

by revenue in the World) is one such behemoth to 

commit to offsite, recently investing in a homebuilding 

start-up company called Plant PreFab, 

who deliver prefabricated homes. This is their first 

move into prefab construction; aside from being 

the biggest online retailer, Amazon is perhaps 

better known for smart home technology. Plant 

PreFab, based in Rialto, California and is set to 

become the latest addition in Amazon's Alexaintegrated 

homes. Amazon's Alexa Fund invested 

in Plant PreFab for their prefabricated single and 

multifamily houses and their plan to use 

automation to build homes faster at lower costs. 

Paul Bernard, director of the Alexa Fund, said 

"Voice has emerged as a delightful technology in 

the home, and there are now more than 20,000 

Alexa-compatible smart home devices from 

3,500 different brands." 

Plant Prefab believes factory-built homes can 

address new building systems and affordability 

through automation. They claim to be the first 

home factory in the nation focused on sustainable 

construction, materials, processes and operations. 

As Paul Bernard stated, "Plant Prefab is a leader 

in home design and an emerging, innovative 

player in home manufacturing. We’re thrilled to 

support them as they make sustainable, 

connected homes more accessible to customers 

and developers." 

Plant Prefab says its approach reduces 

construction time by 50% and cost by 10-25% in 

major cities. 

"We aspire to make the process of building a 

home far easier, faster, and less expensive in 

major cities," says Steve Glenn, Plant Prefab's 

CEO. "And part of this effort involves making sure 

our homes meet our clients lifestyle needs, and 

having greater and more effective smart home 

technology and integration is part of that. Amazon 

is certainly a leader in this domain and we hope 

and expect to learn much from them." 

Amazon already has a deal to pre-install Alexa 

with Lennar, the largest homebuilder in the US; 

the new addition of Plant PreFab could 

dramatically shape the future of Amazon's smart 

home integration… 

Home 2.0 is on its way! 

Google 

Silicon Valley heavyweight Alphabet, Google's 

parent company, is also investing in offsite, to the 

tune of approximately $30 million to provide 

temporary, prefab housing for 300 of its 

employees. 

The Wall Street Journal recently reported that 

Alphabet is making a significant investment in 

modular housing built and shipped in from 

elsewhere by the start-up Factory OS, because 

the current local offerings are so overpriced. San 

Francisco rents have jumped by almost 50% 

since 2010, while home prices have increased 

98% since the bottom of the market in 2009. 

Alphabet's modular apartments are expected to 

be affordable. In a Wall Street Journal article, 

Factory OS founder and CEO Rick Holliday said 

that "a previous project that Holliday built using 

modular technology saved tenants $700 a month 

in rent because of reduced construction costs." 

Facebook 

In a recent blog post, Facebook announced plans 

to turn the 56-acre Menlo Science & Technology 

Park they bought in 2015 into a company town, 

dubbed the Willow Campus. Located across the 

street from the company's current campus, it will 

include a grocery store, pharmacy and shopping 

center. Facebook employees will only have to 

cross the street to commute to the tech giant's 

Menlo Park headquarters. 

The blog post said "Working with the community, 

our goal for the Willow Campus is to create an 

integrated, mixed-use village that will provide 

much needed services, housing and transit 

solutions as well as office space." 

15% of the 1,500 new housing units the company 

plans to build will be affordable, priced below the 

market rate. 

The concept of a model village, such as Willow 

Campus, is nothing new. The 18th and 19th 

century saw a paradigm shift in how employers 

valued their workers. Realising the productive 

benefits from having a happy and healthy 

workforce, many companies ceased to merely use 

and abuse people at will and began investing 

heavily in quality housing for employees, creating 

thriving communities throughout Britain. 

There are at least 28 model villages in Britain, 

built from the late 18th century onwards by 

landowners and industrialists for their workforce 

to live in. 

However, this village won't exclusively house 

Facebook employees. Facebook have stated that 

they plan to open up the units to the community 

at large. This means that Facebook are stepping 

into the housebuilding market, delivering homes 

for the public in a modular way. 

Research suggests that affordable housing is 

much needed in the Bay Area, where prices 

have reached such insane heights that some 

Facebook engineers reportedly asked Mark 

Zuckerberg for help paying rent. 

Apple 

Last year Apple moved into their new campus, 

known as Apple Park. The facility incorporated 

modular construction techniques and was 

supposedly designed with painstaking attention 

to detail to maximize opportunities for creativity 

and collaboration and to capture founder Steve 

Jobs' complex vision for the space. 

The $5 billion campus covers 2.8 million square 

feet, accommodates 12,000 employees in one 

structure and includes a fitness centre, an 

energy plant and large apricot orchards. 

According to Apple, the reason for housing so 

many employees in one facility is so that 

workers build relationships with those outside of 

their team, share ideas with co-workers with 

different specialties and learn about 

opportunities to collaborate. 

The building is divided into modular sections, or 

pods, some of which are intended for working in, 

others for social activities. Everyone from the 

CEO to summer interns will be placed into these 

pods, helping employees build connections and 

discover mentorship opportunities. 

In summary 

The companies mentioned above are advancing 

a variety of construction methods to build 

ambitious development projects that reimagine 

everything from the wood used in homes to the 

ways we think about private vs. communal 

space. 

It goes without saying that offsite has come on 

leaps and bounds in the last few years and will 

only become more and more popular as large 

tech companies such as Facebook and Google 

continue to bring it into the public eye. Attitudes 

need to change, but the future is looking 

modular. 

12 


Apple Park 

The $5 billion campus 

covers 2.8 million square 

feet, accommodates 

12,000 employees in one 

structure and includes a 

fitness centre, an energy 

plant and large apricot 

orchards.

Offsite Education & Student Accommodation 

Connex Offsite a company with big ideas 

Connex Offsite is a bathroom pod manufacturer based in a brand new factory in Newry, Northern Ireland and is part of a larger group of 

companies specialising in Construction, Engineering, Waste Management and Robotics. 

Bathroom pods in recent years have 

revolutionised traditional construction 

methods and are now widely used in 

student accommodation, social housing, hotels 

and Residential apartments. By using off-site 

manufactured products, contractors can benefit 

from a range of advantages including increased 

efficiencies, quality control, reduced site 

management and time-saving. 

Whilst the construction sector faces an 

anticipated 35% future growth, the training deficit 

in terms of skilled workers is currently running 

at a shortfall of 51%*. This lack of onsite 

skills, together with the issue of a 

transient workforce, which can 

only become more critical as 

Brexit progresses. This 

has made Modern 

Methods of 

Construction (MMC) 

a priority for 

construction 

companies, enabling 

them to meet the 

sector demands of 

today and the 

future. 

Comparatively it 

takes six trades to 

supply traditional 

bathrooms on a 

large scale; using 

bathroom pods this 

reduces to one supplier. 

The pods consistent build 

quality gives the 

contractor the 

reassurance 

that they are 

supplying an 

unrivalled 

product that will 

meet the 

anticipated 

results for their 

clients. 

In addition to the 

new 70,000 Sq ft 

factory, Connex Offsite has recently invested in a 

new Howick steel cold roll-forming machine. This 

has made steel framing possible, in favour of the 

more cumbersome and heavy welded box 

sections. The big advantage of this process is 

sizeable weight reduction and the ability to apply 

more flexibility in design without any loss of 

structural integrity. 

Regardless of the uncertainty that overshadows 

Brexit, main contractors who secure their order 

before April 2019 can secure their cost and 

programme for the length of the scheme. 

Bathroom pods are bespoke in design and 

specification to each project. Connex offer the 

service of producing prototypes for the approval 

of the client before entering into mass 

manufacturing. 

Our highly skilled team come together to offer a 

vast array of experience in construction, project 

management, design and delivery. Whatever the 

scheme, large or small, all projects are handled 

personally with the same team from start to 

finish. 

For further information, please contact us on 

02830 800088 or email 

info@connexoffsite.com. 

*All facts and figures from RCIS website 

www.connexoffsite.com 


Need more teaching 

space? 

WERNICK 

It all 

adds up! 

Cost savings of up to 

50% when compared 

to a traditional building. 

Ask about 

energy 

positive 

classrooms 

Specialists in the design and build of modular buildings 

To find out more and view education case studies go to: 

www.wernick.co.uk/education 

0800 18 18 22 

Accommodating people

Education & Student Accommodation 

Off-site Manufacturing – A faster way 

to accommodate student intake 

Although provision of student accommodation, both in the private sector and University has increased over the last five years, demand for 

quality accommodation remains high. 

When considering the provision of 

purpose built student accommodation 

timescales are frequently tight, with 

investors looking for a quick return on their 

investment. 

Premier Modular, is an off-site manufacturer with 

over 60 years’ experience in the market, with a 

strong commitment to research and development, 

ensuring they bring the most innovative products 

to market, for both hire and sale. 

Premier Modular has developed a highly efficient 

light gauge steel frame based factory engineered 

product. Constructed by skilled assembly teams 

in Premier’s 22 acre site in East Yorkshire, the 

system is ideal for a full stand-alone build, whilst 

also suitable for rooftop extensions in tight inner 

city locations. 

The primary benefit of this product is a reduced 

programme; the product is manufactured on a 

flow line and therefore removes any impact the 

weather may have on delivery. Rooms can be 

manufactured at a rate of 25 per week, with 

minimal onsite time. This speed of construction 

not only reduces labour rates and prelims but 

gives a much faster return on investment whether 

clients are selling or gaining a monthly rental 

income. 

Speed of manufacture does not mean 

compromise in other areas though; modules are 

constructed to exacting levels in a quality 

controlled factory environment and with as much 

as 75% of the buildings manufactured offsite, the 

risk of accidents on site is greatly reduced. Impact 

on the local environment is also reduced, with 

reduced deliveries to site and most of the fit-out 

happening at Premier Modular’s factory. 

Premier Modular, working as a supply chain 

partner to Sir Robert McAlpine completed a 5 

storey 206 bedroom student accommodation 

block in Sept 2015. Located in Newcastle Upon 

Tyne city centre it consisted of a mixture of 54 

studio flats, 105 en-suite bedrooms and 2 

accessible en-suite rooms with associated living 

spaces, kitchens and study areas. 

Premier was chosen as the preferred supplier due 

to speed of programme and the high quality finish 

that could be provided. The project was driven by 

an immovable programme requirement of the 

September student intake, Premier efficiently 

manufactured 300 modules fully fitted out and 

decorated in the 

factory - an excellent 

demonstration of the 

enormous time 

benefits realised by 

using the off-site 

system. 

Significantly the 

foundations and 

demolition 

commenced on site 

whilst the modules 

were being 

manufactured – 

ensuring no time was 

wasted in the process. 

Dan Allison, Divisional 

Director – Sales 

Division at Premier Modular said ‘Completing this 

project using off site construction not only gave 

the investors a whole year of additional return, it 

was also a deciding factor in ‘The Foundry’ in 

Newcastle winning ‘Project of the Year Up to 

£10m’ at the Construction News Awards. The 

client is at the centre of everything we do and we 

take great pride in pushing the limits of modular 

design whilst balancing other key project drivers ’ 

‘We always strive for innovation and excellence, 

coupled with a customer-focussed service ethos, 

and are proud and excited to have been 

shortlisted for an Offsite Award on another 

recently completed project. These awards are 

confirmation for ourselves that we continue to be 

forward thinking and creative. 

In a market where an increased rate of build is 

required, building standards are increasing, 

sustainability is of upmost importance and high 

quality lifestyle choices are an expectation – 

Premier Modular’s offsite construction has the 

answer. 

www.premiermodular.co.uk 


College Avenue: Setting the standard for 

Student Accommodation 

Queens University Belfast’s (QUB) brand-new student accommodation at 

College Avenue, beautifully brings together a suite of multi-functional 

systems from architectural aluminium systems’ company, Metal Technology. 

With an overall project value of £35,000,000, the state-of-the-art student 

accommodation brings together effective space optimisation and practical 

design to create a safe space for students in a central Belfast location with 

a range of purpose-built areas to facilitate a balanced approach to study, 

health and wellbeing. 

Spanning 11 floors and an impressive 240,000ft 2 the accommodation 

features Metal Technology’s System 17 high rise curtain walling on all 

facades in combination with System 5-35Hi+ turn only windows, System 

23 louvres and System 5-20D Hi+ doors . These purpose designed louvres 

have been tested to BS6180 for guarding providing a safe environment 

even when the full height windows are fully opened. Key considerations 

when choosing these products included practicality, safety, acoustics and 

thermal performance throughout the building. 

www.metaltechnology.com 

Kingspan Tek adds excitement to 

school dinners 

Pupils at Filton Avenue Primary School are enjoying the benefits of 

offsite construction in their warm, vibrant new dining hall, erected in a 

matter of weeks using the Kingspan TEK Building System. 

Studio LIME proposed a simple pitched roof design, using brightly 

coloured cladding to encourage students to enjoy healthy school 

meals inside. The construction work was completed by Jones Building 

Group during term time. This was one of the reasons the Kingspan 

TEK Building System was specified. Architect, Alex Robertson, 

explained: 

“The Kingspan TEK Building System was chosen to reduce the on-site 

duration of the project and the noise and disruption that goes with it. A 

number of classrooms are located nearby and operated effectively for 

the duration of the project. We were also keen to use the system as it 

allowed us to get a weather proof envelope as quickly as possible, 

reducing the scope for delays.” 

www.kingspantek.co.uk 

Protect Membranes installed in award winning education project 

A combination of Protect construction membranes has been supplied 

and installed at Glasdir School, a modern school building constructed 

to BREEAM Excellent standards using BIM Level 2. 

Built by Wynne Construction and designed by architects Lovelock 

Mitchell, this £10.5 million project involved re-locating two primary 

schools to a brand new shared site in Ruthin, delivering a complete 

solution to client Denbighshire County Council as part of the Welsh 

Government’s 21st Century Schools and Education Programme. 

Manufactured offsite by construction specialist Innovaré using their advanced 

i-SIP technology, an independently accredited Structural Insulated Panel System 

(SIP), the resulting structure was both water and airtight, delivering thermal 

efficiency to a final U-value of 0.15w/m 2 k. The structure led to Innovaré being the 

winners of the Best Use of SIPs category at the 2018 Structural Timber Awards. 

Protect’s TF200 external breather membrane was used externally on the SIP to ensure high water resistance and vapour permeability, minimising the 

risk of interstitial condensation in the wall structure. Internally, Protect BarriAir was used to ensure the integrity of airtightness and to significantly 

reduce heat loss and air leakage through the building fabric. 

Craig Lee, Supply Chain Manager at Innovaré commented, “Over 10,000m 2 of 

i-SIP components including internal and external walls and roof cassettes were 

erected by Innovaré in only 13 weeks, 55% faster than traditional build. By using 

Protect’s membranes we have peace of mind, both in long term performance as 

well as timely deliveries, which helped us to maximise the speed benefits of 

offsite construction.” 

For details of how Protect products can be incorporated into residential and 

commercial builds, please visit the below website, email 

info@protectmembranes.com or call 0161 905 5700, quoting ‘Glasdir School.’ 

www.protectmembranes.com 

Images courtesy of Wynne Construction 


17


© Alan Rowley Photos 

CONNECTING OFFSITE CONSTRUCTION 

Hollo-Bolts by Lindapter were specified for the modular construction of The Spurn Discovery Centre in East Yorkshire. 

Once the modular rooms arrived on site, 

contractors used the Hollo-Bolts to 

connect the Structural Hollow Section 

(SHS) frameworks of the adjoining rooms 

together. The Hollo-Bolt was selected because 

of its high strength capacity and its range of 

independent technical accreditations, including 

the CE Mark approval. The Hollo-Bolt allowed a 

fast and convenient installation process from 

one side only without the need for special 

installation tools or equipment, which resulted 

in an efficient construction schedule. 

This project is featured in Lindapter’s new guide 

to the modular and off-site construction industry. 

The booklet explains how contractors can 

maximise efficiencies and control costs by using 

Lindapter fixing systems. It includes typical 

Lindapter applications in the offsite construction 

industry, such as joining the structural 

framework of modular rooms together, 

connecting balcony extensions, securing steel 

frameworks to ground screws and attaching 

cable trays. The brochure also uses real-life 

examples to demonstrate how Lindapter fixings 

can be used at each stage of the modular 

project from transport and lifting, through to 

securing the framework and modular rooms. 

Since 1934 Lindapter has been pioneering steel 

connections that eliminate the need for 'hot 

working', meaning that there is no damage to the 

existing steelwork and no need for area closures 

or hot work permits. 

For more detailed information use the following 

link to download Lindapter brochures. 

www.lindapter.com/Downloads/Market_Brochures 

…Since 1934 

Lindapter has 

been pioneering 

steel connections 

that enable faster 

build times and 

more efficient 

construction 

practices… 

18 


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ORDER YOUR SAMPLE ON TRESPA.COM


Modular Buildings Meet Demand 

for Bigger & Better Schools 

The demand for new school places and the crumbling state of primary and secondary schools is a pressing issue for Local Councils all 

over the UK. The situation, however, is starting to improve thanks to Government funding – in 2017 a pot of £2.4 billion was allocated for 

their improvement and maintenance. 

Presuming that funding is in place, 

Councils still face a number of challenges 

before building can take place. For 

example, focus on the environment and growing 

energy costs mean that Councils are under more 

pressure than ever to deliver low energy, efficient 

spaces – all while sticking to budget. Safety of 

pupils and minimising disruption during term 

time of course remain pressing issues. 

This need to focus on myriad issues, including the 

small task of ensuring the future sustainability of 

schools in their area, means that Councils are 

uniquely placed to take advantage of modern 

methods of construction. 

Modular schools, delivered to site in segments 

over 2 or 3 days, such as those manufactured 

and installed by Wernick, are helping to solve 

many of the challenges presented by the 

education sector. And new frameworks are 

revolutionising the school building procurement 

process. 

Wernick Buildings’ Divisional Manager for 

Scotland Chris Hart says that there is a “felicitous 

synergy between the education sector and 

modular construction”. Last year, the Wernick 

Scottish division experienced its busiest summer 

to date, tripling its turnover. Summer 2019 is 

expected to be even busier following the Scottish 

Government’s announcement of a £1 billion fund 

for rebuilding and refurbishing Scotland’s schools 

in November 2018. 

Edinburgh, Inverness and Highlands Councils 

took receipt of ten new modular buildings from 

Wernick last summer. Installation, fit out and 

inspection took place over the summer vacation 

and the buildings were ready for pupils upon 

returning to school. 

Ben Wernick, Director of Construction at Wernick 

explains: “Modular building projects can be 

completed up to 50% quicker than traditional 

construction methods as the indoor ‘offsite’ 

construction process can take place alongside 

site and foundations work which also means very 

little delay due to the weather. Finishing buildings 

over the summer holidays means no disruption to 

teaching and no risk to pupils.” 

More and more schools are switching on to the 

speed of factory manufactured buildings, but what 

about the aesthetic? The characterless 

demountables of the past have given way to 

digitally-led, modern designs, indistinguishable 

from ‘on-site’ constructed buildings and lauded by 

architectural firms such as ÜberRaum and 

Glancy Nicholls. 

“The preconceptions are there but the reality is 

that when people walk into a modern modular 

building that Wernick has made, they realise this 

is a big step up from what they’re used to” 

commented Chris Hart, who has found that old 

feelings towards modular buildings die hard: “I’ve 

heard of teaching staff trying their best to avoid 

moving into the new building. Once the building 

has been handed over, they are trying to get in 

there first! They’re warmer, cleaner, bright and airy. 

From a teaching perspective, it’s a considerable 

improvement on a lot of the accommodation the 

teachers are currently working in.” 

Constructing buildings offsite, in a controlled 

environment, means that a building can be made 

water-tight and weather resistant with quality 

controls ongoing throughout the build. Modern 

modular buildings are simple to maintain, are well 

insulated and achieve high EPC ratings – and 

green technologies can be easily incorporated 

into the design to further support their eco 

credentials. 

Chris Hart says that the feedback on Wernick’s 

projects has been overwhelmingly positive, 

adding: “Using factory construction, we can build 

faster, to higher standards, and at any time of the 

year. There are also environmental benefits with 

reduced waste and less emissions. In modular 

construction we can really meet a lot of the 

requirements in the education sector – that’s why 

we think it’s a perfect match.” 

www.wernick.co.uk 

20 

Swansea University 

Active Classrooms

S M A R T C O N N E C T E D S O L U T I O N S 

IN A CLASS OF ITS OWN 

Delivering 110lm/W 

UP TO 50% 

ENERGY SAVINGS 

compared to fl uorescent fi ttings 

Single & twin versions 

Push-fit terminal block 

for FAST installation

article 

New & Improved EZWall Launched 

Euroform Enhances EZWall Brick Cladding System. 

Construction material specialist, 

Euroform, is continuing to widen the 

variety of finishes available in its 

already popular EZWall cladding system range, 

which cleverly combines the advantages of 

modern construction techniques with the 

appeal of traditional brickwork. 

The range has been expanded due to an 

increase in demand for decorative cladding 

applications where installation is quicker and to 

a higher standard than traditionally built 

masonry walls. 

Designed with aesthetics in mind, EZWall 

provides both a decorative and durable finish to 

vertical external walls and can even be matched 

to existing brickwork with its growing choice of 

sizes, patterns, stone and brick types. 

The improved cladding system range is a 

reliable solution for applications on domestic 

and commercial buildings, from garden to gable 

walls. EZWall can be fitted to all types of 

substrates including steel frame systems, timber 

frame systems and block work. 

John Taylor, Technical Director at Euroform, said: 

“There has been increasing demand in the 

market to find solutions for creating authentic 

brickwork designs on buildings without the high 

cost of materials and labour. EZWall is as 

visually attractive as traditional brickwork yet far 

There has been increasing demand in 

the market to find solutions for creating 

authentic brickwork designs on buildings 

without the high cost of materials and labour. 

more cost effective to install on a multitude of 

substrates. Euroform offer an extensive and 

growing range of EZWall designs for any 

project.” 

The cladding system is lightweight at 

approximately 35kg/m2 based on a 15mm slip, 

making it easy to handle and install. Its low 

weight also means EZWall can be used in areas 

that have no load bearing support structure, and 

no specialist tools or clips are required for 

installation. 

The system benefits from full depth mortar 

joints combined with a dual weeping 

mechanism design which allows for superior 

drainage of accumulated moisture, developed 

for years of strength and durability. 

For more information regarding EZWall please 

email info@euroform.co.uk or visit the website. 

www.euroform.co.uk 


Heating, Ventilation & Indoor Air Quality 

Now is the time to transform 

the housing technology mindset 

Before Christmas, Mitsubishi Electric gathered together a panel of industry experts to discuss why the entrenched views and traditions 

of the house building market needs to go through its own revolution to bring about real, sustainable change. The conference, 

‘Transforming the housing technology mindset’, saw talks from TV presenter and architect, George Clarke, Nick Whitehouse, founder of 

Buildoffsite and Mitsubishi Electric’s own experts. Joe Bradbury of MMC Magazine investigates: 

At the event, the panel discussed how the 

traditional building technologies and 

processes have fundamentally remained 

the same for centuries and while so many other 

industries have gone through radical change, the 

domestic construction market has been stymied 

by inaction, government apathy and indecision. It 

was discussed how a need for new solutions and 

new thinking is required to radically change the 

current status quo. 

Ecodan ambassador George Clarke said “When 

you look at almost all other aspects of our life, the 

pace of change and revolution has been 

exceptional. A government report released in 1997 

recommended sweeping changes to the way 

homes are built and heated. When you consider 

this report was released a year before Google was 

founded, you only need to look at the 

technological revolution that followed for this to 

see how far behind the housing industry really is. 

Unfortunately, the housing technology market has 

made very little progress since 1997. We need 

systematic change at a global, national, local and 

personal level to get houses to a standard they 

should be. It’s time for the housing revolution.” 

“We need systematic change 

at a global, national, local and 

personal level to get houses to a 

standard they should be. It’s time 

for the housing revolution”. 

George Clarke. 

poverty out and help 

reduce carbon 

emissions. Among the 

renewable solutions 

discussed were the 

further education and 

widespread adoption 

of heat pumps within 

the housing market. 

“Demand for heat in 

the UK accounts for a 

third of all our carbon 

emissions and half of 

all greenhouse gases. 

This represents a 

huge opportunity and 

is an area that needs 

to change if we are to 

ever cut our own 

carbon emissions, 

and it’s an area that 

can change quite 

quickly if we apply the 

technology” said Martin Fahey, Head of 

Sustainability, Mitsubishi Electric. “Heating is one 

way in which we can take a step towards making 

a difference. We need a mix of low carbon heating 

solutions and better thermal efficiency of 

buildings. Embracing innovative and renewable 

heat sources, like air source heat pumps, we can 

become prosumers – both producers and 

consumers of energy.” 

Speaking on behalf of Build Offsite, the 

campaigning organisation promoting greater 

uptake of offsite techniques, Professor Nick 

Whitehouse highlighted how modular building 

can lower costs by 33%, increase delivery 

speeds by 50% and halve carbon emissions. 

The packed-out event brought together 

architects, specifiers, housing associations and 

heating engineers and showcased the need for 

increased building standards and more use of 

renewable technologies. A video of the talk from 

George Clarke can be found on Mitsubishi 

Electric’s YouTube channel. 

In summary, George Clarke called for the 

industry to stop thinking short-term: “We know 

the pressure is on the construction companies 

to build more energy efficient homes but they 

are not doing enough and not quickly enough,” 

he said, explaining that in essence, we are 

broadly building homes in similar ways to the 

Romans. 

Explaining how modern methods of construction 

and renewable technologies such as air source 

heat pumps mean we can deliver both healthy 

and energy efficient homes, George also 

highlighted how more power from the sun hits 

the Earth in a single hour than humanity uses in 

an entire year, and that this is renewed every 

single day. 

“It has taken us a long time to change our 

mindset with regards to cars, fossil fuels and 

emissions and we are getting there,” he 

explained. “When it comes to our homes, we 

have hardly started and we need to now!” 

les.mitsubishielectric.co.uk 

Innovations discussed by the panellists included 

the need for more modular built homes that can 

be manufactured indoors to increase build quality, 

lower costs by 33%, increase delivery speeds by 

50% and halve carbon emissions. For home 

heating, renewable energy sources were widely 

praised as the best solution to lift those in fuel 


23


Customised Prefabricated Gemtex Solutions 

After a successful fully operational FAT at our factory in Barcelona with our client Box and Charnock, our pre-packaged Adisa boiler skid 

was precisely craned in to their Gresham Road project in Brixton, with only 15mm to spare. 

Gemtex provide off site fabricated plant room assemblies mounted on skid 

platforms. As well as all the benefits of offsite fabrication our boilers are ErP 

2018 ready and meet the new class 6 NOx ratings. 

Our skids and prefabricated solutions are manufactured in line with specific design 

requirements. Produced within the controlled environment of our factory in 

Barcelona, then delivered to site where they can be installed efficiently. 

The Gemtex design team can assist you with the design phase at the start of your 

project so that your plant room is completely suited to the layout and requirements 

of the premises. We will also provide support for the commissioning and end user 

handover processes. 

There are many benefits to purchasing plant room solutions in this way, including: 

• Assistance with the design phase 

• A fully customised layout to suit the constraints of your construction site 

• A plant room that is constructed in a clean environment that is free from dust and 

water, to ensure optimum performance 

• Significant labour savings, resulting in overall costs being reduced 

• All components are ordered through and delivered by one manufacturer 

• Delay-free construction, due to reduction in any potential onsite issues 

• Reduced health and safety risks, and less need for onsite hot work 

• A single delivery for all components, meaning a reduction in site traffic, congestion and therefore, carbon emissions 

• Skids will be witnessed tested in a fully operational condition on our factory test rig, and partially commissioned before delivery to save valuable time after 

installation 

• Various components are available to suit every design (filters, pumps, pressurisation units, tank alarms, etc.) 

Efficient installation of your plant room - Gemtex will manage the construction of your skids and plant room solutions from start to finish. This will be carried out 

in line with our agreed schedule, which we will discuss with you before the project starts. By manufacturing the skids and other components, we make sure that 

your plant room is built to exact specifications. Once delivered to site it’s a simple case of connecting to the services for the buildings heating system. 

www.gemtex.co.uk/skids-and-roof-tops 

EnviroVent releases new Atmos ventilation range 

EnviroVent, one of the UK’s leading ventilation manufacturers, has 

revolutionised its Positive Input Ventilation (PIV) range and added a 

whole collection of new features and functionality to make it even more 

appealing for homeowners, self-builders, social housing providers and 

private landlords. 

Atmos® is the first smart range of PIV solutions with five different units 

available designed to improve indoor air quality and eradicate the problem of 

condensation and mould growth in all types and sizes of homes. 

This includes: 

Atmos® the original unit that gently ventilates the home from a central position on a 

landing. It features an intelligent comfort heater built-in, so the air entering the home 

is at a comfortable temperature. 

Atmos® Air is a PIV unit that is ideally suited for use in the loft space. When summer 

temperatures start to rise above 25 O C in the loft, the unit sources colder air from outside. This not only provides perception cooling into the property 

but also maintains continuous ventilation and is suitable for properties affected by high levels of Radon. 

Atmos® Dual is designed for homes that require a little extra help with dealing with condensation and mould throughout several rooms. With two 

outlets, the unit provides fresh, clean air into multiple areas, even when the rooms are not connected to the central hallway. 

The range also includes an Atmos® Air Dual which offers all these benefits and also draws in cooler air from outside if the loft temperature hits 25 O C. 

All these products within the Atmos® range come with a 10 year warranty, which includes any necessary repair or replacements being installed 

completely free of charge. 

In addition, there is a wall mounted Atmos® unit suitable for apartments and flats that do not have a loft space, which comes with a five year warranty. 

Atmos® has great connectivity as it features the new myenvirovent app, which is the first app of its kind that gives the homeowner complete control of 

their ventilation system at the touch of a button. The app, accessed via most smartphones, can be used to adjust Boost functionality, airflow, heater and 

control summer mode, as well as monitoring filter performance. 

For more information on ventilation solutions from EnviroVent, visit the website or call 0845 27 27 810. 

www.envirovent.com 

24 


Taking 

Building 

Services 

Offsite! 

Kingspan 

Ko 

ooltherm 

® 

Pipe Insulation 

The 

Kingspan 

Koo olDuct ® System 

 

 

 

Specified thermal performance ca an be achieved 

with thinne er Kingspan Kooltherm ® Pipe 

Insulation – modules can be made 

smaller or can 

accommo odate more pipe runs. 

Complete the System with Kingsp pan Kooltherm ® 

Insulated Pipe Support Inserts. 

Enhanced 

Capital Allowances (EC CA) enhanced 

thicknesse es can still be achieved with little impact 

on overall module size. 

The lightw weight nature of Kingspa n products, 

makes the em quick and easy to ins stall in modules. 

For further information: 

+44 (0) 808 168736 

hvactechnical@kingspaninsulation.co.ukngspaninsulation.co.uk 

www.kingspanindustrialinsulation.com 

Glossop, Derbyshire SK13 8GP, UK. 

® Kingspan, Kooltherm, KoolDuct and the Lion Device are Registered Trademarks 

of the Kingspan Group plc in the UK and other countries. All rights reserved.


MVHR-Easy with Posi-Joist 

Cambium Gardens, located within walking distance of the All England Tennis Club in Wimbledon, is a new ‘urban village’ location 

surrounded by protected parkland. It offers 55 apartments and 55 houses in the leafy setting of Southfields, all carefully designed 

around a 200 year old oak tree, believed to have been planted by renowned landscape architect Capability Brown. 

The project is designed to Code for 

Sustainable Homes Level 4, the 

development meets the Lifetime Homes 

standards with 10% wheelchair accessible and 

the Mayor’s London Housing Design Guide. 

About the project 

When McLaren 

Construction (one of the 

UK’s most successful 

privately owned 

businesses) involved 

Howarth Timber 

Engineered Solutions in 

this ambitious project, they 

shared with them a brief to 

construct very energy 

efficient buildings with 

large open rooms but keep the building mass to a 

minimum for their luxury development apartments 

and houses. 

McLaren Construction teamed up with Howarth 

Timber Engineering Solutions, via the carpentry 

installers J A Stott, in order to use their expertise 

and the MiTek PAMIR software to meet the 

required specification. 

Whilst working on the Cambium Gardens project, it 

was identified at an early stage that the pre-cast 

concrete slabs originally specified would not work 

and an alternative in the form of MiTek’s Posi- 

Joists was tabled. This lightweight solution allowed 

for the complex Mechanical Ventilation Heat 

Recovery (MVHR) ductwork & building services to 

be hidden within the floor joist zone, maximising 

the living space within the buildings. 

Howarth Timber Engineered Solutions, using the 

latest EC5 compliant MiTek software PAMIR to 

design not only the Posi-Joist floor joists but also 

using the 3D capabilities of PAMIR, ensured that 

the MVHR ductwork was able to traverse 

the floors of the luxury 

apartments and houses. 

HTES 

worked 

directly 

as an 

integral part of the project design team producing 

interactive 3-D models and BIM compatible 

design solutions so that the entire design team 

could check and sign off the proposals before any 

work was carried out on site. The MiTek PAMIR 

software is able to produce 

not only .dwg drawings, but 

also .pdf files, CAD 

drawings as well as 

Industry Foundation Class 

(IFC) files – to be imported 

into Revit. This coordinated 

approach saved both time 

and money on the build for 

the Contractor, Architect, 

Engineers and M&E 

designers. 

About MiTek 

Based in Dudley in the West Midlands, MiTek 

specialise in the development of software 

solutions for structural timber engineering and the 

provision of steel connector products for floor and 

roofing systems. 

Since its foundation in the mid-1960's, MiTek have 

gone from strength to strength, growing both 

organically and through acquisition to become 

market leaders, operating worldwide by delivering 

leading software solutions that are second to none. 

PAMIR 

The modern roof designer needs to be able to 

design a roof very quickly. With several new 

enquiries arriving on their desk every day, they 

need software solutions that enable them to 

design and quote roofs in no time at all. This is one 

of the many reasons that it was used within the 

Cambium Gardens project. 

PAMIR's speed of framing is undoubtedly 

amazing. 

In just four clicks of the mouse the user can input 

this sizeable building, fully framed and ready to 

price. With PAMIR you can quickly edit the 

building dimensions and watch the roof 

dynamically re-frame. Whether you are moving 

walls, adding an attic room, changing the roof 

pitch, or mirroring roof features, Pamir's powerful 

dynamic framing allows you to make the change 

in seconds. 

PAMIR combines roof layout, truss engineering 

and high quality CAD output features, all into one 

integrated software platform. This means that roof 

designers have just one environment to learn and 

are more productive, faster. 

Developed by MiTek’s large European team of 

software professionals, PAMIR has been 

enthusiastically welcomed by the industry and 

looks set to change roof and floor design as we 

know it. 

In conclusion 

Lend Lease, head of residential Richard Cook, said 

“Cambium will create a vibrant new community in 

the heart of Southfields and we are delighted to 

welcome councillor Cook and pupils from Our 

Lady Queen of Heaven today to mark this 

significant development milestone: the start of 

work on site. 

”A highly sustainable scheme, Cambium delivers 

the best of contemporary and eco-friendly living 

for new and existing residents in the borough of 

Wandsworth.” 

www.mitek.co.uk 

26 

Customer: Lend Lease 

Client: McLaren Construction 

Contractor: McLaren Residential 

Architect: Scott Brownrigg Associates 

Structural & Civil Engineers: Walsh 

Posi-Joists Supplier: Howarth Timber 

Engineering Solutions 

M&E Design & Install: Emico 

Posi-Joist Installer: J A Stott Joinery


27


How Modular Approaches are 

Transforming Building Services 

2018 felt like a breakthrough year for offsite construction, with developers across the country embracing 

modular methods and the government dedicating £420m to the development of new technologies. 

A product BIM Object is available for the pipe 

insulation, supporting the use of level 2 BIM 

and offsite construction methods. 

Kingspan Kooltherm Pipe Insulation was installed as 

part of the modular service construction of Airedale 

International Air Conditioning’s Headquarters. 

The building service sector has been 

amongst the most successful adopters of 

these approaches, achieving significant 

reductions in the scale and complexity of onsite 

work along, with greatly improved predictability. 

BIM 

As with other areas of the construction industry, 

the rising use of offsite approaches in the service 

sector is intimately linked to the adoption of Level 

2 Building Information Modelling (BIM). 

Building service engineers have traditionally been 

required to take a pragmatic approach to their 

work. Service specifications are often not finalised 

until projects are well progressed and practitioners 

typically must work around late changes in the 

design and layout of spaces when they arrive on 

site. In contrast, the collaborative approach of 

modelling, sharing and integration within Level 2 

BIM, is now allowing service designs to be 

effectively ‘locked in’ before work even begins on 

site. 

To give a sense of the scale of this change, the 

Building Engineering Services Association 

estimates that a typical BIM model may comprise 

just 70 standard drawing components for the 

main structure, compared with over 70,000 for 

mechanical and electrical services . 

The ability of modelling software to automatically 

flag clashes has proven especially beneficial, 

allowing issues to be resolved at the design stage. 

The accuracy of these models is further aided by 

product-specific BIM objects, which are available 

from online libraries such as BIMstore. This 

certainty in design has been fundamental to the 

adoption of offsite approaches. 

Offsite 

By moving fabrication of services to dedicated 

manufacturing facilities, chaotic building sites and 

occasional scheduling conflicts are replaced with 

a clear, controlled and safe process. Large modular 

service units can be fabricated in preassembled 

standard configurations to a reliable schedule. 

Fabricators are readily able to access all sides of 

the sections without restrictions, allowing focused 

quality control, particularly on large and complex 

service modules. Problems with availability of 

skilled labour can also be reduced as staff are 

able to operate from a single location. 

Once completed, sections can be held in storage 

until the site is ready to receive them and larger 

modules can be lifted into place with heavy 

machinery, often eliminating the need for 

scaffolding. In addition, as large, complex sections 

can be installed in a single action, the time spent 

working on site is cut down and site waste is 

greatly reduced. 

Several firms have already reported significant 

improvements in operating efficiency through the 

use of BIM Level 2 and modular construction. For 

example, NG Bailey has highlighted typical cost 

savings of up to 35% (including labour reduction 

costs of 40%) and overall programme time savings 

of 90% . 

In Practice 

One project to benefit from the use of offsite 

service approaches is Airedale International Air 

Conditioning’s Headquarters. Following a serious 

fire, the building needed to be quickly 

reconstructed. BAM Construction used BIM at the 

design stage, and made the decision to deliver the 

industrial development as a turnkey project to help 

save time and resources. 

Nick Howdle, project manager from BAM 

Construction, discussed the project: “Using BIM 

has been an invaluable resource for ensuring that 

we could accurately estimate the costings and 

timings, including effectively overlapping M&E 

installations without incident. We would have 

struggled to achieve the programme without 

offsite methods. BIM helped with clash detection, 

and we had zero snags with the pipework. On a 

£1.3 million package that is highly unusual, if not 

unheard of.” 

The use of BIM also helped the project team to 

identify solutions which could meet the 

demanding performance criteria. For example, all 

pipe insulation used on the project was required to 

have FM Approval, whilst the pipe insulation fitted 

within the research and development test 

chamber had to support an extreme temperature 

range of between -20 to +50 degrees Celsius. The 

product BIM object and accompanying literature 

for Kingspan Kooltherm Pipe Insulation showed it 

could meet these requirements with a slim 

insulation thickness. 

Next steps 

The rise of modern methods of construction is 

only set to continue this year, with five government 

departments now committed to making a 

‘presumption in favour’ of offsite manufacture for 

suitable capital programmes. By utilising modular 

building services within this approach, project 

teams can help to achieve further savings in 

project timescales and costs. 

www.kingspanindustrialinsulation.com 


New thinking for modular sector 

As one of the UK’s largest off-site manufacturing businesses, Caledonian knows a thing or two about modular buildings. It’s one of the 

reasons why the company has grown to a turnover in excess of £50m and with a goal firmly set on doubling this over the next 2 years 

you get the distinct impression they’re set to change how the industry works. 

Having been founded over 50 years’ ago 

and now operating from a 40-acre site in 

Newark, Nottinghamshire, they’re unusual 

in having one of the longest trading histories in 

the modular sector. 

Success has come about by sticking to what it 

does best; high quality modular accommodation 

that is delivered to site with up to 96% of the build 

completed in its quality assessed manufacturing 

facility. Proof is in the pudding and they don’t get 

much bigger than the £53m Hinkley Point C 

worker accommodation contract that was 

successfully delivered in 2018. Effectively creating 

in ‘new town’ in just 51 weeks, it shows the 

capability of modular construction and how, if the 

government’s rhetoric on solving the UK’s housing 

crisis once and for all translates into action, 

Hinkley is the shape of things to come. Housing 

providers should take note of what Caledonian has 

achieved – effectively creating a modular new 

town at Hinkley that houses 1,496 workers in just 

51 weeks. 

Caledonian’s innovative modular building system 

means that programme savings of up to 50% or 

more are possible compared with traditional forms 

of construction. And the programme can be more 

predictable than when using conventional 

methods as well as reducing waste and number of 

deliveries to site. 

Project delivery 

A central pillar to the company’s growth is the 

ongoing focus on quality and project delivery. The 

underpinning methodology is to take a traditionally 

constructed building and apply latest 

manufacturing techniques to drive efficiencies. 

The three core areas of this are the use of BIM, 

design for 

manufacturing and 

assembly (DfMA) and 

lean manufacturing 

techniques. 

The results are 

replicable, too. The 

latest is a £25m 

project that involves 

Caledonian working 

with Bowmer & 

Kirkland to 

manufacture high 

quality student 

accommodation as 

part of a £54m 

development for the 

University Campus of 

Football Business, 

First Way Campus in 

Wembley. 

The 680 bedrooms will be manufactured and 

installed by Caledonian and, similar to Hinkley, will 

be 96% complete prior to shipping to site. That 

was one of the main reasons they were selected 

for this project; because they could show how the 

modules would help meet the strict deadline dates, 

which required handover by July 2020 in time for 

Euro 2020. First Way Campus is situated a few 

minutes’ walk from Wembley Stadium, and will 

include a mix of purpose-built student 

accommodation as well as academic, office and 

outdoor space. 

Fire compliance capabilities of the modular system 

also featured highly in the selection process, due 

to the high rise nature of the development. It rises 

to 11 storeys and that really shows what is possible 

with the company’s modular building solution. 

Caledonian gave the client and design team 

confidence post Grenfell, providing a preengineered 

fire compliant modular solution 

suitable for a development of this scale. 

Damian Flood, CEO of Cole Waterhouse, said: “We 

liked the modular building solution proposed by 

Bowmer + Kirkland and its supply partner 

Caledonian for First Way Campus because it was a 

practical way of meeting the strict schedule. We 

are providing Wembley and the UCFB students 

with a fantastic campus that will include a number 

of facilities for students including purpose built 

accommodation (678 beds), seminar rooms and 

staff office spaces as well as amenities such as a 

café style restaurant, a gym and library/IT suite.” 

Developers Cole Waterhouse brokered a deal with 

Unite Students, a leading provider of student 

accommodation in the UK. Caledonian has 

incorporated the Unite requirements into the 

design to provide a higher standard student living 

experience than is traditionally expected. 

Modular Mindset 

Caledonian is a company with an eye firmly set on 

the future and as Chief Executive Officer Paul 

Lang explains: “Our ability to deliver to a strict 

schedule and have an existing fire compliant 

solution made a compelling proposition for First 

Way Campus. We are able to achieve consistent 

project delivery by investing in BIM, design for 

manufacturing and assembly (DfMA) and lean 

manufacturing. In combination we believe that it 

will help us raise industry standards across the 

board. Our long term goal is to lead change in the 

industry by establishing a ‘modular mindset’ with 

clients and developers.” 

www.caledonianmodular.com 


29

product news 

McAvoy awarded £15 million contract to build hospital wing 

Due for completion in Spring 2019, the 6,500m 2 three-storey building will be linked to the existing hospital. The first floor will be fitted out as part of this contract 

to accommodate one of the UK’s first purpose-designed Ambulatory Care units. The new wing is being constructed by McAvoy using an advanced offsite 

solution to reduce the build programme by half to less than 12 months. This will help Northumbria Healthcare Trust maintain its position as a world leader in 

emergency medicine. 

Raymond Millar, Construction Director of The McAvoy Group, “We are again 

pushing the boundaries of offsite construction. We have developed a hybrid 

solution which incorporates both offsite and in-situ building methods and are 

maximising fit-out in the factory for this first phase to enhance quality and 

reduce disruption to staff and patients.” 

www.mcavoygroup.com/healthcare 

Hadley Group to exhibit at Midest 

Hadley Group will bring its technical expertise to the Midest exhibition 

in Lyon later this year. The international show, which runs from 5-8 

March at the Eurexpo Centre will cover a number of industrial 

subcontracting sectors. 

Visitors to Hadley Group’s stand at stall 6N92 will get a first-hand 

insight into its comprehensive range of industry-leading products. 

Speaking about the company’s participation, Tom Rodenberg, Account 

Manager for Overeem, part of Hadley Group, commented: “At this year’s 

event we’re really focussed on 

promoting our vinepost range, as well 

as our custom roll formed products. 

Thanks to the patented UltraSTEEL® 

process, our steel profiles have a 

number of advantages over 

alternative options. We can design 

bespoke steel profiles to match a 

company’s exact requirements.” 


REHAU Smart Plumbing Manifold shortlisted 

in H&V Awards 

The finalists for this year’s H&V News Awards have been announced and 

REHAU’s Smart Plumbing Manifold has been shortlisted in the Domestic 

HVAC Product of the Year - Components & Peripherals category. 

The H&V News Awards celebrate and reward excellence to the most 

forward-thinking businesses and products and highest achievements 

across the building services industry – and after 25 years 2019 sees the 

awards celebrating its Silver Anniversary. 

REHAU opted to put forward its market leading Smart Plumbing Manifold 

due to its innovative design and purpose. The modular, compact product 

offers a solution for control of 

water distribution, designed for use 

in utility cupboards where space is 

at a premium. It’s time-saving for 

the installer as it only takes a 

matter of seconds to install and 

provides visual checking to ensure 

it is secure and tight. 

www.rehau.uk 

Time saving new Pattress panel for dryliners 

PATTRESS PLUS is the time saving, dust reducing, noise eliminating 

new OSB3 panel that dryliners have been dreaming of. 

The latest product from innovative timber panel manufactures MEDITE 

SMARTPLY will be available to order from 1st February 2019. 

Ideal for contractors who construct plasterboard partitions, PATTRESS PLUS 

panels feature a continuous recess along one side that is designed to 

accommodate ‘C’ studs without the need to cut in slots on site. 

This key design feature means that each panel sits flush against the stud 

flange, holding steady while you simply screw the other side into place. 

The finished result means a massive reduction in dust - as no cutting is 

required, drastically reduced noise - due to fewer power tools, and much less 

time spent cutting and installing panels which can save hours, if not days, on 

big installations. 

PATTRESS PLUS panels are available in thicknesses of 15mm or 18mm, widths 

of 397mm or 597mm (to fit 400mm and 600mm stud centres), and lengths of 

1250mm or 2397mm, in line with leading plasterboard partition specifications. 

Head of Marketing and Brand at MEDITE SMARTPLY, Stuart Devoil, comments: “PATTRESS PLUS panels have been created to meet a clear market need. 

When speaking to Dryliners and contractors dealing with plasterboard partitions, it became clear that installing pattressing is one big headache. We found that 

the current boards they use require cutting on site, which creates large amounts of dust and noise, that in turn creates additional health and safety risk, plus the 

use of additional metalwork and fixings adding time and complexity, all resulting in extended installation times. We just wanted to reduce the risk and complexity, 

whilst saving them some time into the bargain. 

With our expertise in developing innovative timber panel solutions we knew that this latest technology will help tradespeople to create a safer working 

environment while saving them time and money. We’ve already trialled the product with one plastering contractor who said he’ll never go back to traditional 

panels after using PATTRESS PLUS.” 

For more information on PATTRESS PLUS, and to find your nearest stockist, please visit the website. 

www.mdfosb.com/en/smartply/products/pattress-plus 


Stargard 

The original“Warm to the 

touch” handrail 

4mm thick (4,000 microns) PVC 

over galvanised 

tubular steel 

www.handrailsuk.co.uk/ stargard 

Email: sales@sgsystems. 

co.uk 

Tel: 

01473 

240055 

5 

- warm to the touc ch handrail 

S targard 

Il l umine - LED illuminate d handrai l 

ntinel - stainless steel bal ustrad 

e 

S 

e 


31

Article 

Managing 

heat, air & 

moisture 

movement 

in modular 

buildings 

For modular buildings to be energy efficient, healthy, and 

moisture free what is required is a holistic approach to a total 

system which manages the balance of Heat, Air, Moisture 

Movement (HAMM), considering an integrated approach to 

airtightness, insulation and condensation control. 

Buildings with very low rates of air leakage 

require correspondingly higher levels of 

ventilation as part of a balanced, design 

approach. It’s important to bear in mind that 

ventilation is controllable, and therefore can be 

accounted for within the overall design, whereas 

uncontrolled air leakage is not. 

The incorrect specification or installation of 

effective thermal barriers will lead to unmanaged 

heat loss, impacting directly on the energy 

efficiency of the building and its systems. 

Airtightness and vapour permeability 

Air movement is important in the building 

envelope both infiltration and escape. We need to 

control interior conditioned air (whether heated or 

cooled) escaping and exterior air infiltrating that 

puts more pressure on heating or cooling 

mechanisms internally. Airtight membranes are 

key in this area whether vapour and air 

open/closed or variable. 

Moisture vapour will pass through the various 

layers of any construction by both convection and 

diffusion. The objective is to ensure, by design, that 

the moisture vapour can disperse to the outside 

atmosphere without being cooled to below 

dewpoint temperature, thus eliminating 

condensation and associated problems such as 

mould growth. 

To avoid the occurrence of excess condensation, 

which can result in mould growth and damage to 

the building fabric, designers should assess the 

amount of water vapour likely to be generated 

within the building and determine the resultant 

increase in internal vapour pressure above that of 

external air. They should then consider the 

physical properties of the construction separating 

inside from outside. 

Why airtightness is crucial to modular building 

design 

There is absolutely no question that an integral 

part of modern building design is influenced by 

energy efficiency. In the EU it is estimated that 

buildings account for approximately 40% of 

energy consumption and are responsible for some 

36% of CO2 emissions. Closer to home, around 

45% of UK CO2 emissions come from the built 

environment, (27% from domestic dwellings and 

18% from non-domestic). 

Airtightness improves energy efficiency 

As thermal insulation requirements have 

increased over the last few years, the proportion of 

energy lost through air leakage has become more 

evident. The ever-increasing thermal insulation 

required will, however, be rendered largely 

ineffective unless the airtightness of the structure 

itself is addressed. Air leakage greatly reduces the 

effect of thermal insulation; therefore if energy 

efficiency is to be improved within buildings, this is 

the most critical area to focus on. 

In addition to improved insulation, energy efficient 

heating systems will also be ineffective if warm air 

can escape the building and cold air can seep in. 

This is reflected in the fact that total space heating 

costs in an airtight construction may be 

considerably less than in a leaky one. 

Air leakage through cracks, gaps, holes and 

improperly sealed elements such as doors and 

windows can cause a significant reduction in the 

performance of even thermally insulated 

envelopes. Architects are increasingly turning to 

air barrier membranes as an essential part of the 

design process in achieving the most effective 

means of controlling and reducing air leaks. 

In terms of the energy efficiency of a building, 

uncontrolled air flow will almost certainly have a 

major impact. Initial heat load calculations for 

heating and cooling equipment will usually make 

an allowance for a level of natural infiltration or 

uncontrolled air flow. The higher the infiltration 

rate, the lower the energy efficiency of the building. 

Efficiency levels can be affected by both natural 

and mechanical air movements. The forces of wind 

and stack effects will lead to a level of air 

infiltration and subsequent efficiency loss. Sealing 

the shell of the building and any un-designed 

holes can reduce the impact of wind and stack 

effects and improve the overall energy efficiency. 

Airtightness protects building fabric and reduces 

maintenance costs 

Unmanaged or uncontrolled air flow will act as a 

carrier for moist air, drawing it from outside in, or 

pulling it from inside out, into walls, ceilings, and 

roofs. The impact of uncontrolled moist air 

movement can have a long-term detrimental 

effect on the durability and life of the building. This, 

in turn, can lead to:- 

• Decay of organic materials such as timber 

frames. 

• Saturation of insulating materials, thus reducing 

their insulative effect (further increasing heat 

loss). 

• Corrosion of metal components. 

• Frost damage where moisture has accumulated 

on the cold side of the insulation 


The design of an effective airtight system will 

reduce the risk of uncontrolled moisture 

movement, and the potential for damage caused 

by condensation within the building fabric. 

Effective airtightness design 

The two main ways to achieve airtightness in the 

building envelope are internally or externally, or in 

other terms, ‘inside of the services zone’ or ‘outside 

of the services zone’. 

Traditional use of internal air barriers can be more 

complex and costly to install, due to the need to 

accommodate building services such as electrical, 

lighting, heating and drainage systems. An internal 

air barrier is only as good as its installation. If all 

the service penetrations are not adequately 

sealed, performance will be compromised. 

For many years, external air barriers have been 

commonly specified in North American building 

design and construction. By moving the air barrier 

to the external side of the structural frame, external 

air barrier systems such as Wraptite from A. 

Proctor Group allow for an almost penetration-free 

airtight layer, which can be installed faster and 

more robustly. This offers an effective but simple 

system comprising a self-adhesive vapour 

permeable air barrier membrane, plus vapour 

permeable sealing tape, Wraptite Corners and 

Wraptite Liquid Flashing, and provides effective 

secondary weather protection while preventing 

trapped moisture and air leakage. Far simpler than 

internal options an external air barrier system like 

Wraptite will maintain the envelope’s integrity, with 

less building services and structural penetrations 

to be sealed, and less room for error. 

Incorporating Wraptite in the design makes sense 

Wraptite is a patented external air barrier 

membrane system, which offers manufacturers 

and designers of modular and off-site buildings 

the ability to reliably and comfortably exceed 

current airtightness requirements. Wraptite is the 

only self-adhering vapour permeable air barrier 

certified by the BBA and combines the important 

properties of vapour permeability and airtightness 

in one self-adhering membrane. This approach 

saves on both the labour and material costs 

associated with achieving the demands of energy 

efficiency in buildings. 

• Complies with use 

on buildings of high 

rise and over 18m 

under Part B 

amendments made 

in November 2018, 

Membranes need to 

be Class B,s3,d0 or 

better, with Wraptite 

at Class B,s1,d0*. 

• Included within 

BS8414 testing with 

cladding 

manufacturers. 

• EPDM not needed 

to the frame of the 

building as Wraptite 

is self-adhesive and 

continues across 

the whole envelope 

of the building 

against the 

sheathing board 

and the frame of the 

building. 

• Less EPDM around 

window details due 

to Wraptite lapping 

into the building at 

junctions. 

• Corner detailing for 

opening and 

movement joint 

interfaces are easily 

treated. 

• Improved 

airtightness and 

may negate the use of a VCL totally from the 

design internally, meaning easier a quicker 

install of dry lining package. 

• Hydro-Thermal Modelling (WUFI) showing the 

difference of not using a VCL within some 

constructions benefits the building further. 

• Improving airtightness may allow you to change 

thickness or type of insulation used when 

modelled through SAP or SBEM. 

• No need to tape sheathing boards as Wraptite 

is positioned across the whole board. 

Student 

Accommodation, 

Portsmouth 

Parker Tower, 

Covent Garden 

• Testing has seen 

results as low as 0.5 

m3/(h.m2) @ 50PA 

carried out at 

Windtech on a 

window façade 

panel. 

• By using Wraptite on 

the external, this may 

show you an 

improvement on 

making the building 

watertight, allowing 

your cladding 

package to come off 

the critical path and 

internal works to 

start earlier, and also 

internal works may 

not be installing a 

VCL so the site 

program is 

potentially quicker. 

High-performance off-site solutions 

The A. Proctor Group Ltd has been providing 

solutions and products to the construction 

industry for over 50 years. The company has 

been developing vapour permeable membranes 

and vapour control layers for over 25 years, and 

provides an extensive range of superior highperformance 

products suitable for modular and 

off-site construction. 

Dedicated in its approach to helping you to 

achieve best practice, effective and reliable 

solutions to meet your modular building 

requirements in line with building regulations and 

energy efficiency, the A. Proctor Group team of 

highly experienced industry professionals and 

technical advisors is on at hand to guide you and 

support you from design throughout the 

construction process. 

The A. Proctor Group range of products include 

unique off-site solutions for the following sectors: 

• Private and social/affordable housing 

• Purpose built student accommodation 

• Self-build projects 

• Hotels 

• Education buildings 

• Healthcare including hospitals, health centres 

and healthcare facilities 

*tested over 12mm calcium silicate board / fibre 

cement board as per BS EN 13238:2010. All 

tests carried out to EN 13859-2 standard. 

www.proctorgroup.com 


33

Article 

Modular solutions take 

the chill off the Antarctic 

Funding has been secured by the Polish Ministry of Science and Higher Education for a new Polish Antarctic Station designed by 

Kuryłowicz & Associates. The project is to be located on Admiralty Bay, on the southern part of the island of King George in the South 

Shetland Archipelago, about 120 km from the Antarctic coast, 14 000 km from Poland. 

FACT FILE 

Client: Institute of Biology and 

Biochemistry PAN (Polish Academy 

of Science) 

Usable area: 1348m 2 

Building volume: 4490m 3 

Architecture: 

Kuryłowicz & Associates 

Building Services: 

Buro Happold 

Structural Engineers: 

Buro Happold 

The design of the station is shaped by a 

detailed functional program, the extreme 

environmental conditions of the site and 

by a modular construction strategy which has 

been imposed by site access restrictions. 

The result is a highly efficient tripartite 

ensemble which provides scientists with rational 

research space as well as a ‘home away from 

home’ atmosphere while the sinuous shape of 

the building’s exterior envelope seeks to capture 

the mystery of arctic life and articulate the thrill 

of exploration for its visitors. 

The station’s shell is made from prefabricated 

panels of timber, layers of acoustic and thermal 

insulation and is finished in a robust skin of 

copper/aluminum alloy sheets which is resistant 

to wind, high-speed projectiles and sea breeze 

corrosion, allowing easy maintenance and 

achieving a desired gold/brass aesthetic 

reminiscent of futurist sculpture. 

The islands extremely difficult weather 

conditions, which consist of: high katabatic 

winds, sub-zero temperatures and high levels of 

atmospheric precipitation as well as the 

absence of the necessary technical 

infrastructure on site, mean that the building is 

designed in a modular system. The modules will 

be pre-assembled in Poland, then transported to 

the island in parts via sea containers and then 

will be put together by a construction crew 

without the use of heavy equipment. 

Construction will take place during an annual 

weather window which lasts for three months 

from November to March. 


tools & equipment 

Quality is the main driver towards MMC use, NHBC Foundation 

report finds 

The term ‘Modern Methods of Construction’ (MMC) is often mentioned when discussions occur 

about the need to build more new homes. Richard Lankshear, Innovation Manager at NHBC, 

explains more about this approach… 

At NHBC we have a specific way of assessing MMC Systems so we can understand the detail of the 

system and support our customers by carrying out a thorough review. 

As such we identify MMC as offsite manufacture, innovative technologies and other non-conventional 

methods of construction that form the structure and envelope of the home. This includes sub-assemblies, 

volumetric and panelised systems manufactured off site as well as site-based MMC. 

Not all offsite manufacture is necessarily a Modern Method of Construction as many conventional forms of 

construction are assembled offsite. We do not treat a system as MMC if the construction is described in 

the NHBC Standards and where the system components can be inspected on site. 

We know that vast majority of homes are built with traditional cavity masonry – 74% in 2017 with 16% in 

timber frame and 1.5% in light steel frame with the balance in framed structures or unique systems. 

However, what we are seeing is an overall much greater interest in MMC systems. In the past we received 

between four and eight innovative systems to review each year, but this changed dramatically from about 

2015/16 with over 30 systems received in 2016. Last year saw a record 38 new systems submitted. 

And this is also seen in the investment by house builders and housing associations in their own offsite 

production and the emergence of new, sizeable, manufacturers of MMC systems. The Government’s White 

Paper and the MHCLG report “Modernise or Die” set out the opportunities for greater use of MMC and industry is certainly responding. 

The 2018 NHBC Foundation report “MMC: Who’s doing what”, identified “Quality” as the primary driver towards the use of MMC. This potential raising 

of standards is welcomed by NHBC, but it is not always achieved. What is clear from our review of multiple MMC systems is that quality is only 

achieved through investment – investment in design, in manufacturing procedures, in training and in construction. 

NHBC is the UK’s leading warranty and insurance provider for new homes. We set standards for NHBC registered builders and work with them to help 

them improve the construction quality of the homes they build. 

www.nhbc.co.uk/mmchub 

+353 47 80500 

combilift.com 


35

External Building Envelope 

The Evolution 

of MMC 

It was after the Second World War the UK saw a rapid demand for house building and solutions needed to be provided quickly 

and efficiently. 

It was during this time that new techniques 

and products were introduced to the 

building industry to meet these demands, 

but unfortunately there was an oversight in 

quality due to the extreme quantity that was 

being produced leading to many publicised 

failures. 

Sixty years on and modern methods of 

construction (MMC) has seen a staggering 

evolution and investment. Legislations have 

forced a change in the way we build, based on 

climate change, performance based building 

standards and the code for sustainable homes. 

Much of what MMC promotes is efficiency, 

quality, environmental performance, 

sustainability and short time scales using better 

products and processes. The methods consist 

of offsite construction where parts are 

manufactured and assembled in a factory and 

brought to site already complete, or onsite 

construction which 

brings components 

and systems 

together onsite. 

At Premier 

Guarantee we have a 

product and system 

approval process 

which has been 

developed to help 

manufacturers gain 

accreditation under 

our technical 

requirements. For 

developers and 

builders this is 

important as we 

want to make sure 

the MMC products 

and systems you use 

…Much of what 

MMC promotes is 

efficiency, quality, 

environmental 

performance, 

sustainability and 

short time scales 

using better 

products and 

processes… 

are approved by us and accepted by our 

warranty cover. 

We are continuously working with 

manufacturers to expand our approved MMC 

products and systems. To see which ones have 

already been given the seal of approval, please 

see our product approval page. 

www.premierguarantee.com 


SIP design & manufacture Full house kits Extension kits 

Housing Hotels Student Accomodation Education 

Healthcare Leisure Retail Commercial 

SIPCO are at the forefront of Structural Insulated Panels (SIP) technology, offering complete design, 

manufacture, supply and installation project management services - which can be tailored to suit specific 

project requirements. SIPs are an advanced structural timber construction method, offering superior 

insulation, structural strength and airtightness - all in one composite panelised system. 

SIPCO has built its reputation on high quality products and customer care, with a market leading blend of 

guaranteed performance and competitive pricing. A culture of continual innovation has resulted in reduced 

installation costs, improved performance and a commitment to quality, sustainability, health and safety. 

0151 424 5346 • info@thesipcompany.com 

www.thesipcompany.com


THE FUTURE 

OF URBAN 

DEVELOPMENT 

IS LOOKING UP 

Estimates vary on how many homes could be created in UK cities by extending buildings vertically. Recent studies 

suggest that there may be space for as many as 20,000 to 40,000 new rooftop dwellings in the centre of London alone. 

Furthermore, The National Planning Policy 

Framework (NPPF), as of July 2018, 

includes specific reference to in support of 

upward living. The document states that planning 

decisions should support the use of the ‘airspace’ 

above buildings especially if “the development 

would be consistent with the prevailing height 

and form of neighbouring properties and the 

overall street scene”. 

The availability of land, particularly in cities, is a 

significant challenge to meeting the current 

demand for housing. Roof Top Developments 

(RTD) negate this issue by utilising the existing 

building with no need to find new land and enable 

the creation of additional storeys without 

increasing the overall footprint of the building. The 

added value of this approach is that, unlike the 

majority of greenfield developments, it allows 

much needed housing to be created in the areas 

of cities where land is most scarce. Furthermore, 

the planning permission process is often much 

simpler as the transport infrastructure and 

amenities are already in place. 

One of the most effective ways of achieving 

upward extensions to buildings is through the use 

of modular and panelised building solutions. 

These RTD systems consist of a lightweight, 

robust steel frame construction, which can be 

built into panels off-site, craned into position and 

assembled. The external cladding, insulation and 

finish can then be applied, and the new flats 

connected to the building’s services. The 

properties can then be fitted out in the same way 

as a traditional build. 

This innovative approach by Langley enables the 

building to benefit from any number of additional 

storeys providing planning permission can be 

secured, the existing building has enough 

structural capacity and the layout allows sufficient 

access for residents. In some cases, a structural 

frame can be used to support the additional 

storey. This is added to the outside of the building 

and concealed with cladding to maintain the 

aesthetic of the building. 

In addition to utilising the existing roof space, 

vertical development using modern methods of 

construction also has a number of specific 

benefits over building on green- or brownfield 

sites. As there are no costs for the ground works 

that would be required for a new or in-fill 

development, homes can be created at a much 

lower cost per unit. This cost effectiveness is 

particularly valuable for social housing providers 

and local authorities where making best use of 

often limited capital is vital. 

Additionally, panelised RTDs provide an increase 

speed within the construction process, reducing 

time on site. The work can often be carried out 

while the building is still occupied, further 

minimising the disruption for current residents. 

Despite the benefits of extending upwards, one of 

the barriers to widespread adoption is acceptance 

by building owners and leaseholders. Here there 

is scope for local authorities, housing associations 

and the build to rent sector to lead the way in 

normalising the approach. These organisations 

can, and in some cases, are already, engaging 

with their tenants to explain the intended work 

and formulate a plan that will deliver tangible 

benefits to existing residents. Adding a further 

storey delivers best value when planned as part 

of a wider regeneration of the property. Once a 

template for development has been created the 

process can be replicated across a number of 

buildings to maximise the use of land in an area. 

Roof Top Developments offer a quick, simple and 

cost-effective way of creating additional dwellings, 

supporting existing communities in towns and 

cities. While small scale vertical extension of 

private homes is not a new concept, the largescale 

developments that will help address the 

issues with housing demand in cities has not yet 

achieved widespread adoption. Despite this, 

recent changes in government policy and 

forward-thinking organisations embracing the 

concept have helped begin this process and give 

developers confidence in the model. 

www.langleystructures.co.uk 


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EFFICIENCY BOOST FOR LOCAL BUILDERS 

Spantherm is an innovative ground floor system from Creagh Concrete which is being adopted by a growing number of local 

house builders. 

The regulations have been designed to make 

house builders consider more than just the 

physical performance of the structural envelope, 

they are now obliged to consider each individual 

component’s impact on the buildings overall 

energy efficiency and particularly the removal of 

thermal bridging. 

All of these factors are combined within 

Standard Assessment Procedure (SAP) 

calculations and this adds a further dimension 

for builders to consider as they seek the most 

cost effective specification for each house type. 

Creagh Spantherm in situ 

As housebuilders increasingly explore the 

opportunities for new ideas to reduce 

labour onsite and boost efficiency in the 

build it makes sense that they start with the 

ground floor. The initial appeal of Spantherm is 

clear, because a typical floor on a detached 

house or a pair of semis is fitted onsite in less 

than two hours. 

Most builders opt for the work to be completed 

by Creagh’s expert fitting team, requiring no 

labour from the house builder; however the floor 

can also be ordered on a supply only basis for 

installation by the builder’s own team. Once in 

place and grouted, the floor achieves its full 

structural capability with 72 hours but building 

activity can commence on perimeter walls within 

24 hours. 

Practicality 

The speed of construction saves around a week 

off the total schedule when compared to the 

typical poured concrete floor alternative. A 

further advantage is that the factory made 

Spantherm floor come to site as single units 

combining the precast concrete and insulation 

material, so there is no requirement to stock or 

handle loose insulation. This feature also means 

that the installation of Spantherm is not weather 

dependant and creates zero waste onsite. 

Each Spantherm floor is manufactured to the 

house plans provided, taking account of the 

required loadings and the positioning of services 

which penetrate the slab. Creagh’s technical 

team however, are on hand to measure the 

builder’s sub-floor works prior to manufacture, so 

any site issues are eliminated. 

The Creagh flooring team work closely with each 

site manager to ensure the floors are available to 

call off when required and this level of 

cooperation greatly simplifies the process for 

the builder. 

Performance 

Everyone can understand the advantages of 

faster completion however Spantherm brings a 

second major benefit in the form of its excellent 

thermal performance and the impact that brings 

within the most recent building regulations. 

Getting off to a good start with an energy 

efficient floor system is essential to a strong 

fabric first solution. 

Designing and building energy efficient homes 

to meet current regulations can be a complex 

process but installing a high performance 

insulated ground floor is always a good start. 

Thermal modelling of the 

Spantherm/wall junction 

(parallel to external wall) 

Reducing heat loss 

The design of Spantherm insulated concrete 

floor is optimised to provide the maximum 

practical insulating effect by combining high 

performance EPS and structural precast 

concrete in a single factory built unit. This 

provides a thermally efficient system which rates 

favourably against building regulation 

requirements and provides U values which are 

superior to that achieved by many alternative 

flooring products. 

Combatting thermal bridging 

Spantherm’s reinforced concrete structure has 

been designed in a way to minimise the thermal 

bridge at all the junctions between the wall and 

the floor units. It is this excellent thermal 

efficiency which gives the builder that good start 

to their total SAP calculation which can reduce 

the reliance on the use of expensive renewable 

technologies. 

Please cantact Creagh Concrete on 

01636 831043 or email 

hoveringham@creaghconcrete.com 

www.creaghconcrete.co.uk 

20 [°C] 

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“A typical floor on a detached 

house or a pair of semis is fitted 

onsite in less than two hours…” 

41

article 

A ‘modular mindset’ is needed to 

tackle London’s housing crisis 

London needs 66,000 new homes each year. However, in recent history, nothing like this capacity has ever been delivered. In 2016-17, 

there were just 41,371 net additions to London housing stock. Less than 5,500 affordable homes were completed in 2017-18, compared 

with an average of over 10,000 per year in the last decade. Analysts suggest offsite is the answer. 

MMC Editor Joe Bradbury investigates: 

Recent research by New London 

Architecture (NLA) called for a ‘Modular 

Mindset’ to revolutionise the way 

housing is planned, procured, designed and 

built to accelerate the delivery of high-quality, 

affordable and sustainable homes for London’s 

citizens, now and in the future. 

NLA’s research paper, entitled ‘Factory-Made 

Housing: a solution for London?’ examines the 

impact of factory methods on the future of 

housing delivery in London. The report, informed 

by interviews with leading professionals at the 

forefront of delivering factory-made housing, 

shows the potential for these construction 

methods to make a positive contribution to 

London’s housing needs – highlighting the 

range of manufactured systems available today 

and the opportunities that digital techniques 

and processes can offer. 

Change begins within 

Moving construction from the site to the factory 

environment is not just a case of tweaking 

existing processes or adapting current models, 

says the report. Using factory methods to 

design and build new homes at scale requires a 

complete rethink of established attitudes to 

commissioning, planning, procurement, finance, 

design and construction. 

The extent of the housing crisis 

It’s no secret that housebuilding needs to 

increase in the UK. It is predicted that a total of 

250,000 homes need to be delivered each year 

in order to tackle spiralling house prices and the 

critical shortage of affordable homes. This target 

has constantly been missed - with figures 

showing that only 184,000 homes were 

completed in England in 2016/17. This is more 

than in recent years, but still below the 2007/08 

pre-recession peak of 200,000. 

With only 63% of projects delivered on time and 

only 49% delivered to budget, it’s clear to see 

that traditional building practices, whilst still 

integral, are falling short of meeting major 

challenges on their own. 

Consider that London alone needs 66,000 new 

homes each year. Despite this, in 2016-17, there 

were only 41,371 net additions to London 

housing stock. Less than 5,500 affordable 

homes were completed in 2017-18, compared 

with an average of over 10,000 per year in the 

last decade. 

Many are looking to Mayor Sadiq Khan for 

answers. Almost half of London’s need is for 

social rent, but only 14% of all home starts so far 

in this Mayoral term are for social rented homes. 

The Mayor has received £4.82bn to deliver 

116,000 affordable home starts by March 2022. 

This year’s target range for starts is 14,500 to 

19,000 - but only 2,400 were recorded in the 

first six months of this year. 

Recently, the Chair of the Housing Committee, 

Sian Berry AM, said “The Mayor is letting down 

Londoners, he promised us more affordable 

housing but so far has fallen very short of his 

promises, particularly on social housing which is 

our greatest need. 

“With young and lower-income people suffering 

the most from the housing crisis, we can’t wait 

much longer for his policies to kick in. 

“The Mayor must fulfil his pledges. It is in his 

power to ease the housing crisis and meet his 

targets – especially as he has received new 

funding. 

“There is now no excuse for genuinely 

affordable housing to be out of reach for 

Londoners who want a secure home.” 

Changing behaviours 

Adopting new technologies is not just a matter 

of innovation in materials and construction 

methods but open communication, transparency 

of data and information sharing, and a challenge 

to established beliefs about responsibility for 

delivery and risk. A collaborative stance based 

on long-term partnerships and agreements – 

breaking down the barriers between disciplines 

– rather than an adversarial, competitive, shortterm 

outlook will improve quality, add value and 

reduce risks. Manufacturing high-quality 

repeatable components and units demands a 

system-based approach that focuses on 

continuous improvement through the cycle of 

assessment, prototyping, analysis, fabrication 

and installation. 

David Jones, Modular Integration Director at 

Legal and General commented “There is a lot of 

talk about embracing ‘modern methods of 

construction’, but I don’t think that policymakers 

are strict enough in terms of indicating exactly 

what this means in terms of percentage of 

manufactured elements – we need more clarity.” 

Jonathan Falkingham, co-founder and creative 

director at Urban Splash, argues that for this 

reason government should intervene in largescale 

developments. He said “The current highly 

risk-averse procurement process for public land 

heavily favours the larger housebuilders – 

smaller housebuilders simply don’t have the 

required balance sheets – opening up land to 

more housebuilders would deliver greater 

variety in housing typologies, higher market 

penetration and speedier delivery.” 

Key benefits of factory-made housing 

• Speed of delivery – 30 to 70% quicker than 

traditional construction methods 

• Higher quality – due to controlled production 

• Reduced transportation and community 

impact – less noise, pollution and deliveries 

• Flexible and diverse – a solution for almost 

every site and scale of project 

• More environmentally friendly – improved 

energy efficiency, using certified timber 

projects 

• Less affected by the shortage of skilled labour 

in the construction industry – improving the 

view of construction and attracting a younger, 

more diverse workforce 

• Small, restricted sites can be used – offering 

reduced impacts of noise, vehicle movements 

and flexibility for building on irregular plots 

Peter Murray, Chairman of NLA, said “Factorymade 

homes are advocated by Government and 

Mayoral policies to speed up housing delivery in 

London and across the UK. But we must be 

mindful that the same level of consideration is 

given to design, place-making, amenity, 

infrastructure and public realm. We must not 

repeat the mistakes of the 1960s.” 

Graeme Craig, Director of Commercial 

Development at Transport for London, added 

“London desperately needs affordable housing 

and it’s vital that the industry considers fresh 

and creative approaches to tackle the challenge 

head-on. To provide these homes we need to 

unlock complex, challenging sites, sometimes 

impossible to deliver using conventional 

methods of construction. We’re working with a 

range of partners, including EVA Studio and 

Apartments for London, to develop innovative 

solutions that will help to overcome some of the 

barriers traditionally faced, and support the 

Mayor in delivering more affordable homes 

across the capital at pace.” 


In London, less than 

5,500 affordable 

homes were 

completed in 2017-18, 

compared with an 

average of over 

10,000 per year in the 

last decade

Fire Protection & Safety 

Change is in the air 

Government departments are pouring over technical data and preparing new directives, trade bodies are examining every aspect of 

potential market implications. No, this is not another missive on BREXIT, but the reality of the changing world concerning Fire Doors and 

related risk critical products. Change is in the air and everyone should be aware of the urgent need to specify truly compliant products 

that play a significant role in the process of safety. 

Following the tragic events of the Grenfell 

disaster in 2017, a greater understanding 

began to emerge regarding the lack of a 

holistic approach to fire safety and the evident 

shortcomings of custom and practice, where the 

cheapest solution took precedence over properly 

certified and tested fire safe product solutions, 

such as fire doors and fire door assemblies. 

The recently published document Building a Safer 

Future, commits the government to a programme 

of reform which includes: 

• The implementation of the Hackitt 

recommendations 

• Create a more effective regulatory and 

accountability framework 

• The introduction of clearer standards and 

guidance 

• A vision to create a culture change 

The result of these actions will mean tougher 

sanctions for those who disregard residents’ 

safety, and more rigorous standards. In fact the 

Government has committed to carrying out a full 

technical review of Approved Document B. This 

will propose potential changes to a range of 

technical issues within the current Approved 

Document. 

While we all await the inevitable changes to 

legislation and good practice, it is encouraging to 

learn that Dame Judith Hackitt’s independent 

recommendations will form a cornerstone of the 

changes to come. Shaping future product 

specification, installation and ongoing use 

throughout the life cycle of buildings. 

For specifiers struggling to evaluate fire door 

solutions in this changing world, especially in 

respect to residential high-rise and complex 

buildings. It is comforting to know that Vicaima 

fire performance 

products offer a 

benchmark to the 

industry, with 

exceptional test 

evidence and 

incorporating key 

elements of Hackitt’s 

recommendations 

that less enlightened 

manufacturers have 

yet to adopt. Third 

party accreditation is 

assured, as Vicaima 

adhere to not one but 

two nationally 

recognised and 

highly reputable 

bodies to verify the 

performance of our 

products, namely 

BWF-Certifire and 

BM TRADA Q-Mark. 

In each case 

traceability is always 

visible with the use of 

tamper evident labels 

and plastic plugs to 

provide clear 

understanding of fire 

rating and of course 

origin of manufacture. 

This simple but effective marking, alongside a 

detailed inkjet stamp system to identify exact date 

of manufacture, enables Vicaima to establish 

complete control of our products throughout their 

lifecycle. 

Of course the fire door in itself does not provide 

the complete solution, this can only be achieved 

with compatible and rigorously tested 

components, including the correct frame and 

ironmongery. This is why alongside fire doors, 

Vicaima also manufacture an extensive range of 

door kit solutions to create a complete, fully tested 

assembly via our Easi-Fit and Portaro brands. 

These products provide complete peace of mind, 

with a full scope of performance characteristics 

for current and future housing specifications, 

namely: 

• Fire Tested to BS 476 Part 22 and BS EN 

1634-1:2014 

• Secure by Design approved products 

• Acoustic performance, both inherent and 

additional as required 

• FD30 and FD60 rated, plus smoke seals to 

FD30s and FD60s 

• Durability with DD171 and EN 1192 severe 

duty rating 

• Mobility provision via glazing and dimensional 

flexibility 

• Environmentally robust (all products are FSC 

Certified) 

• Longevity with a 10 Year Guarantee 

As specialist fire performance door 

manufacturers Vicaima have long understood the 

need to go above and beyond industry norms and 

simple compliance to provide cutting edge and 

safe solutions that are fit for today’s market. 

Vicaima has always prided itself on the 

construction of its fire doors, never cutting 

corners or compromising, regardless of whether 

it’s a humble painted door or a fashion conscious 

designer product. Performance and design go 

hand in hand at Vicaima with innovative designs 

options encompassing finish foil, veneer, 

laminates and paint lacquered surfaces; including 

cost effective products for demanding projects. 

Whatever future regulatory changes lie in store 

for our industry you can be assured that Vicaima 

fire performance offers appropriate solutions and 

the first choice for a safer tomorrow. 

www.vicaima.com 


Modern Methods of 

Construction 

We work with 

industry to help 

deliver long-lasting 

quality homes. 

•From component materials 

and design, to onsite 

installation and connection 

•System appraisal and 

acceptance 

•Inspection of the whole 

building to NHBC Standards 

•Backed by NHBC Buildmark 

warranty and insurance 

Talk to us... 

Call us now on 0344 633 1000 Email techservices@nhbc.co.uk 

or visit www.nhbc.co.uk/mmchub 

NHBC is authorised by the Prudential Regulation Authority and regulated by the Financial Conduct Authority and 

the Prudential Regulation Authority. NHBC is registered in England & Wales under company number 00320784. 

NHBC’s registered address is NHBC House, Davy Avenue, Knowlhill, Milton Keynes, Bucks MK5 8FP. 

M589 10/18

Fire Protection & Safety 

SE Controls creates dedicated smoke 

control solution for newcastle USB 

Newcastle University’s innovative and multi-award winning Urban Sciences Building (USB) is using a combined smoke control and 

environmental ventilation solution that incorporates a SHEVTEC control system, which was engineered by SE Controls to meet the 

unique requirements of the project. 

Photography © Kristen McCluskie 

www.kristenmccluskie.com 

“The Urban 

Sciences Building 

is a technological 

and sustainability 

tour de force.” 

developed the new OS2 TipTronic SHEVTEC 

Controller, which is dedicated to Shueco’s 

TipTronic actuator system, enabling it to provide 

effective smoke and heat exhaust ventilation 

(SHEV) to the building. 

Following the production of a detailed design, 

which included integration matrices, schematic 

drawings, operational documentation and 

installation details, SE Controls installed more 

than 40 of the new OS2 TipTronic controllers at 

the USB. 

Designed by architects, Hawkins Brown, 

the 12,800m 2 USB is the first structure 

to be completed on the 24 acre 

Newcastle Helix development and is home to 

the university’s world leading School of 

Computing, as well as providing extensive 

teaching and research facilities focused on 

digitally enabled urban sustainability. 

The building incorporates a diverse range of 

innovative technologies, sustainable design 

features and fresh thinking, which includes a PV- 

T array, rainwater harvesting and a 560m 2 wild 

flower green roof, as well as a bio-dome, which 

uses waste CO2 heat and water from the building 

to grow food for the university’s restaurant. Also, 

4,000 digital sensors and embedded computing 

technology make it one of the UK’s most 

monitored high performance buildings. 

As energy efficiency and sustainability are key 

aspects of the building design, these principles 

were also carried through to the glazed façades, 

curtain walling, environmental ventilation and 

smoke control systems. 

Cladding and glazing systems specialist, Dane 

Architectural Systems, were involved from the 

early stages of the project and used Schueco FW 

60 + SG, with AWS 114 ventilators including 

TipTronic concealed actuators. 

To ensure they could meet the demanding 

design intent of the system, which required these 

vents to be linked to the BMS for managed dayto-day 

ventilation, Dane Architectural turned to 

SE Controls a specialist contractor capable of 

providing a fully compliant solution. 

As the Automatic Opening Vents (AOV) have 

specific zone requirements and operate in banks 

of 3 for normal ventilation needs, SE Controls 

designed the operation of the smoke control 

system to maintain the functionality and flexibility 

of the TipTronic control, while integrating with the 

system and providing effective smoke ventilation 

to the building in the event of a fire. 

To achieve this, SE Controls worked in close 

collaboration with Dane Architectural and 

Photography © Kristen McCluskie 

www.kristenmccluskie.com 

Andrea Hayward, SE Controls Senior Key 

Account Manager on the project, explained:“ The 

Urban Sciences Building is a technological and 

sustainability ‘tour de force’ which reflects the 

advanced research activities undertaken at the 

university and we are delighted to have our own 

innovative technology incorporated within its 

design.” 

Further information on SE Controls products, 

solutions and projects can be obtained by visiting 

the website, emailing sales@secontrols.com or 

calling +44 (0) 1543 443060. 

www.secontrols.com 

46 


product news 

Hadley Group acquires Hadley Steel 

Framing Ltd 

Global cold rolled 

manufacturer of steel 

solutions with real world 

applications, Hadley Group 

is pleased to announce 

the acquisition of Hadley 

Steel Framing Ltd (HSF). 

HSF will continue to 

operate as a stand-alone 

business but will have the 

resources of the wider 

Hadley Group available for 

support. 

Hadley Group originally 

acquired a 50% stake in Hadley Steel Framing Ltd (HSF) ten years 

ago, supporting the growth of the company by manufacturing and 

delivering its cold rolled steel framing products. This latest 

development in HSF’s ownership means it will be business as usual 

with no changes to the manufacturing or delivery aspects of the 

business. Hadley Group will provide HSF with the stability and 

security that comes with being part of a large international group. 

Hadley Group operates across the globe, providing a significant 

breadth of product solutions across a diverse market. The company’s 

expertise, market insight and manufacturing capabilities have 

positioned it as a world leader in advanced cold rolled steel 

technology. 


Monarflex protects workers and public alike at 

Merseyside site 

Protection 

against the 

strongest 

winds that 

Merseyside 

can summon, 

Monarflex 

Airflow FRA 

containment 

netting is 

protecting both 

workers and 

passers-by 

during the 

£38.25m Category A fit out of India Buildings, one of Liverpool’s most iconic 

buildings. 

Built between 1924 and 1932, India Buildings is a nine-story steel-framed 

complex clad in Portland stone that was awarded Grade II listing for its 

architectural quality. 

Distributed by BMI, Monarflex Airflow FRA is an exceptionally strong flameretardant 

containment netting that has been specially developed for high 

and low-rise locations where strong winds are a significant risk. It is suitable 

for DigiWrap printing so that clients can protect their machinery, workforce 

and passers-by from debris while promoting their business from what then 

becomes a massive billboard. 

Made from a woven polypropylene composition with flame retardant 

additives, Monarflex Airflow FRA has open and closed woven sections that 

are ideal for high-rise buildings as the open sections release air pressure 

on the rest of the material. 

www.bmigroup.com 

Guide to 21st Century heating & plumbing available from REHAU 

REHAU has announced the latest in its series of guides for M&E and building services engineers, ‘Making the Connection – key 

considerations for M&Es specifying pipe fittings in 21st Century heating and plumbing systems’, is now available for free-download. 

Part of the ‘Build Your Legacy’ series, the guide focuses on the key services provided 

in any building, whether domestic or commercial, and gives advice on best practice 

in terms of product and system selection. Selecting the right products that are easy 

to install, reliable and cost effective can be a balancing act for those running a 

business, particularly for the sole trader – something the guide aims to tackle. 

Today’s modern heating and plumbing applications present many challenges and the 

guide explores each in depth. They include; price pressure, lead times and the 

potential penalties involved, increasing skills requirements, how best work with other 

trades involved in the project and logistics and site handling. 

Options for pipe fittings is closely examined and how a small component can have a 

significant impact on a building project. The benefits of using soldered or brazed 

joints is discussed, as well as how compression fittings, press fit and push fit 

alternatives all work and what each of these can bring to an individual project. 

Materials used in piping also vary significantly and the guide specifically looks at the 

use of copper versus plastic and what should be considered prior to selection, 

usually depending upon the requirements and operational parameters of the project. 

The guide also features five top tips for specifying and installing 21st Century pipe 

fittings and key points include avoiding the need for hot works, choosing a 

component that can be easily inspected and use of pipe liners. An easy to follow 

guide to compression sleeve technology is also included, which is a new technique 

and product that removes the need for deburring and calibrating of pipes, offering a 

major time saving solution. 

www.rehau.uk/buildyourlegacy 

48 


jjI- JOISTS. SMARTER THAN YOUR AVERAGE I -JOIST. 

JJI-Joists have an answer for everything built-in. No matter how demanding your job, JJI-Joists are in a class of their own. Solid 

timber flanges and OSB web make them light but very strong and easy to work with (creating service holes couldn’t be simpler). 

Our environmental credentials are also second to none. Add to that our technical brains - on hand to answer questions - and our 

design software that gives smart cost-effective answers, and your choice has to be intelligent JJI-Joists. Well, you’d be daft not to. 

WEB: www.jamesjones.co.uk/ewp EMAIL: jji-joists@jamesjones.co.uk

article 

OFFSITE MANUFACTURING VITAL TO THE 

SUCCESS OF LONDON BRIDGE 

As offsite manufacturing continues to provide innovative and valuable solutions to major infrastructure projects, Nick Brautigam Project 

Director at building envelope specialist Prater discusses its benefits in relation to the successful delivery of the London Bridge 

redevelopment. 

With the after effects of Mark Farmer’s 

2016 government review still rippling 

through the industry today, a number of 

main contractors are now making offsite 

fabrication a requirement on all large-scale 

projects – a trend that will undoubtedly become 

an ever-increasing focus in the future. This 

methodology is by no means new, however with 

construction output on the increase and clients 

looking to appoint project partners that can truly 

add value to the process – it comes as no great 

surprise that the use of offsite manufacturing is 

increasing. 

Here at Prater, we are now incorporating elements 

of offsite manufacturing across a number of our 

projects and are continuing to proactively invest in 

our inhouse factory facilities to further develop our 

offsite solutions. A fantastic example of our use of 

this methodology is our development of London 

Bridge Station. The station, which serves 125,000 

commuters a day, underwent a major 

redevelopment programme, a six-year-long 

upgrade that now offers an increased number of 

routes and destinations with a better travel 

experience for passengers. 

London Bridge faced a common challenge posed 

to developments in large, congested cities; lack of 

space onsite. On top of this, the station is the 

fourth busiest in the UK, meaning that speed of 

work onsite was essential, creating as minimal 

impact to the stations day to day running as 

possible. Offsite manufacturing played a crucial 

role in our extensive scope of works on the 

development, where the complex structure of the 

canopies, tight timescales and restricted access 

meant that an onsite solution was not practical. 

After early engagement with our dedicated supply 

chain partners and detailed discussions with 

Network Rail, Costain and the architect Grimshaw, 

a decision was made to invest in building a fullscale 

constructability prototype of a 60m-long 

platform section in North Yorkshire. This was then 

dismantled and rebuilt, with the idea to challenge 

the buildability of the project in line with site 

restrictions and constraints, enhancing the end 

quality of the build and the confidence of all 

parties in the final result. This innovative 

methodology provided insight, not only into the 

aesthetic of the finished build but also the 

performance of the end solution – whilst still 

being able to check the accuracy of the build 

against the 3D model. 

To assist collaborative working, Prater established 

an offsite manufacturing facility to house all its 

supply chain partners for the project. Severfield 

was responsible for steelwork and Prater worked 

on the roof cassettes, whilst the M&E contractor 

was responsible for installing the interfaces, 

incorporating: lighting; PA equipment; PIR sensors 

and security cameras. To ease the build process, 

the cassettes were built into adjustable transport 

frames – allowing the team to access the 

underneath sections of the structure. 

Even with work being undertaken 24/7 by a 

number of teams onsite, the sheer scale of the 

project demanded the redevelopment be 

completed over five years. However, by 

manufacturing much of the roof canopies offsite, 

one lift with a power crane could lift up multiple 

elements at a time, speeding up the overall 

installation and the amount of time the machinery 

was needed onsite. In addition, skilled workers 

who created the prototype offsite were utilised 

during the installation process of the cassettes – 

removing the learning curve and ensuring the 

installation was consistent. This guaranteed the 

highest quality of delivery and also further saved 

time on installation. 

The prefabrication of the building components in 

an industrialised factory environment also ensured 

an increased level of consistency, and the 

reduction of any defects. For larger, more complex 

infrastructure projects such as London Bridge, 

where bespoke designs are required, the ability to 

construct a test version is crucial to accessing 

strengths, weakness and potential issues with the 

project. 

Perhaps the most significant benefit that arose 

from offsite manufacturing was that it allowed us 

to reduce risk, by taking work away from the site 

and in a controlled environment. As 90% of the 

cassette manufacture and build was taken offsite 

and only 10% comprising the installation and 

fitting of infill panels onsite, most of the work was 

undertaken at ground level – significantly 

reducing risk across the entire project by reducing 

unnecessary work at height. In fact, we can 

proudly say that over all the 650 thousand manhours 

spent on the project there was not a single 

serious incident. 

Modernisation and progression are key to the 

future of the construction industry, and offsite 

manufacturing is an ideal technique for achieving 

this. We have seen a dramatic increase in the 

number of clients opting to utilise our offsite 

manufacturing capabilities, and the type of work 

being undertaken is setting new benchmarks for 

the construction industry – particularly when it 

comes to complex roofing projects. London Bridge 

provides a prestigious example of how offsite 

manufacturing can ensure the success of a 

project, and we are extremely proud to have 

achieved the Costain Blue Standard – a set of 

performance statistics that envelope our 

performance on London Bridge across a range of 

activities. Working alongside Costain over the last 

five-years, and achieving the Blue Standard, 

exemplifies the excellent support the team has 

delivered to Network Rail and Costain. We hope to 

see more companies across the industry adopting 

this methodology – so together we can continue 

to successfully and safely push the boundaries of 

construction. 

www.prater.co.uk 


A2 

ersapanel 

V l ® AILABLE 

AVAILABLE 

NOW 

Combining the known and 

proven advantages of cement bond ed 

particle board with the ad ddition of Euroclass “ A2 ” certification, delivering 

enhanced fire performanc ce and suitable for buildings over 18m 

Exceptional performance in th he presence of moisture when compared with exterior 

gypsum boards as cut edges do not require sealing to prevent degradation 

• A high mass, robust exterior lining to optimise 

• CE marked according to BS EN 

acoustic performance of the building envelope and 13986:2004+A1:2015 

there is no time limit of exposure before covering 

• Independently tested as A2-s1,d0 reaction to fire 

with other elements of the façade 

according to BS EN 13501-1:2007+A1:2009 

• Offers superior mechanical performance compared 

• Can be provided in a pre-fabricated kit to reduce 

with exterior gypsum boards 

site works 

• Helps improve the air tightness of façades when 

p p g ç 

sealed at any joints 

Trade Flyer: Specific technical advice is recommended before proceeding with any transaction. 

• Available as 2400mm x 1200mm boards in either 

10mm or 12mm thickness 

• A wide range of systems may be applied over A2 

® 

V ersapanel including: 

- Approved insulated render systems 

- Terracotta cladding systems 

- High performance cladding systems 

- Traditional brick coursework 

Full technical information available from your local office. 

Contact our technical/sales team on 

01925 860999 

info@euroform.co.uk 

www.euroform.co.uk

a.aa MMC M11 52pp Web

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