PSBJ March 2014 Supplement

www.psbj.co.uk

Floors, Walls & Ceilings Focus March 2014

Reducing risk

Avoid costly flooring replacement with trusted systems

A material challenge

Architects choose materials for 21st century Paddington station

Protective coat

Help buildings retain their character with compliant measures

Floors, Walls & Ceilings Focus

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Floors, Walls & Ceilings Focus

Welcome Editor Hannah Frackiewicz hannah@mixedmediainfo.com 01622 873229 Managing Director Sam Ball sam@mixedmediainfo.com 01622 873229 Publication Manager Steve Gull steve@mixedmediainfo.com Account Executives Tom Murray-Scott tom@mixedmediainfo.com Bobby Stoneman bobby@mixedmediainfo.com Studio Manager Chris Lilly chris@mixedmediainfo.com Production Ben Bridgeman ben@mixedmediainfo.com Artworker/Sub-editor David Perry david@mixedmediainfo.com Accounts Simone Jones simone@mixedmediainfo.com Terms and Conditions:

Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and return addressed envelope. No responsibility will be taken for drawings, photographs or literary contributions during transmission or in the editors hands. In the absence of an agreement the copyright of all contributions, literary, photographics or artistic belongs to Mixed Media Information Ltd. The Publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed in editorial material or otherwise do not necessarily represent the view of the publisher. The Publisher does not accept any liability of any loss arising from the late appearance or non publication of any advertisement.

Front cover:

Philip Durrant photography

...to the

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Floors, Walls & Ceilings Focus

he surfacing within a building is integral to the aesthetics of the project and longterm performance. Floors, walls and ceilings all possess added benefits that make working, learning and living far more productive and comfortable environments.

Getting the specification right from the outset can deliver significant cost and time savings.

Flooring underlayments and screeds for instance must be specified correctly in order to avoid costly replacements earlier than expected. Turn to pages 10 and 18 to find solutions that combat this risk!

Elsewhere in this dedicated supplement, PSBJ rounds-up the latest solutions available on the market from fire retardant coatings to help period buildings meet regulations, to ceiling tiles that excel in levels of sound absorption. Among the highlights we hear from Sika flooring who share their top tips on flooring specification and we profile a striking wall and ceiling panel solution, designed to unlock design potential.

For further enquiries about any of our contributors or if you wish to comment on a particular issue within this product area, please do not hesitate to get in touch at the usual address.

Hannah Frackiewicz

Hannah Frackiewicz - Editor, PSBJ Magazine

Contents 5

Aesthetic appeal: The Knauf Vinova solutions for walls and ceilings provide complete design freedom – and at the same time offer the precision of a high tech, fully engineered product.

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Specific requirements for specification: With public sector building projects, the product specification process must strike the right balance between performance and cost. Here Sika’s Flooring Product Manager shares his top tips for flooring specification.

9

A sound installation: A combination of mineral and metal tiles and canopies from Armstrong Ceilings were specified for the refurbishment of Braintree District Council’s former offices in Witham, Essex.

10 Withstanding the traffic: A series of Mapei systems, including Mapei’s Topcem binder and S1 adhesive, were chosen to enable fast installation and provide a surface suitable for Birmingham New Street’s interchange station.

A combination of mineral and metal tiles and canopies from Armstrong Ceilings were specified for the refurbishment of Braintree District Council's former offices in Witham, Essex. See Pg 09.

12 Ultimate protection: Envirograf explains how two striking architectural buildings have been able to retain their character thanks to its innovative solutions.

14 Surfaces that work hard: Surfaces had to fulfil a requirement very specific to the Paddington Integrated Project – the shade of the finish had to be finely tuned to avoid glare. Following a consultation Carillion turned to Wheelabrator Impact Finishers.

18 Time-saving solution: Mixed Media Information Pear Platt, Woodfalls Farm, Gravelly Way, Laddingford, Kent, ME18 6DA Tel: 01622 873229 Fax: 01622 320020 www.psbj.co.uk www.mixedmediainfo.com

The smoothing underlayment, Stopgap 1200 Pro, from F. Ball and Co was specified to provide a professional flooring solution for Dumfries and Galloway hospital pharmacy.

Public Sector Build Journal

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Floors, Walls & Ceilings Focus

SEAMLESS PERFORMANCE

Online Enquiry 076

SIKA FLOORING No faults. No defects. No joins, blemishes or shortcomings.

From the moment it takes to the floor, Sika is a seamless work of art in two-part, economic, coloured epoxy resin. A perfect balance of function and aesthetics. As much at home in storage and assembly halls as it is in hotels and galleries.

4 find Public Build Journal To outSector more, visit www.sikaflooring.co.uk

Floors, Walls & Ceilings Focus

Unlock design potential Aesthetically versatile and offering outstanding performance features, the Vinova panel from Knauf - a leading UK manufacturer of lightweight building materials and systems - extends the potential uses of the gypsum fibre panel to a new level.

Ease of installation James Leaning, Business Development Director for Knauf, said: “The Knauf Vinova solutions for walls and ceilings provide complete design freedom – and at the same time offer the precision of a high tech, fully engineered product. Knauf Vinova panels are prefabricated and very easy to install making Knauf Vinova an excellent choice for architects.”

The digital print boards can be supplied in either a uniform or standard finish while the HPL board is available in either a single colour

or wood finish. The CPL boards are supplied in standard coatings of white/grey, silver/grey, anthracite and beech/maple while the boards featuring real wood veneer are available in maple, birch, beech, oak, ash and walnut.

The lacquer boards are supplied in clear lacquer as standard but can be supplied in RAL and NCS colours on request, while all the boards in the range can be supplied in bespoke finishes as required for individual projects.

The lacquered and wood veneer boards can be bent to a radius of up to 300mm – a semi-circle – while the HPL and CPL boards can be supplied curved if required, and so extend the interior design possibilities even further.

Ideal for interior walls and ceilings, Knauf Vinova panels are especially suited for applications subject to strict fire regulations.

Formaldehyde-free, the panels are noncombustible and deliver outstanding fire performance: under the EN13501-1 the panel was classified as A2 – s1, d0, meaning that it made no contribution to fire, produced no smoke or flaming droplets or particles.

The Vinova panel from Knauf extends the potential uses of the gypsum fibre panel to a new level

Standard board sizes are 12, 16, 18 and 25mm thick and measure 3000, 2500, 2000, 1500, 1200 and 600mm long and 600mm wide. Other thicknesses and sizes are available on request. Vinova panels can be used alongside other Knauf products, and will fall under the Knauf product and system warranties.

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onsisting of a gypsum fibre panel, Vinova finished surfaces can be digitally printed, continuous pressure laminate (CPL) or high pressure laminate (HPL) coating, real wood veneer, lacquered or paint.

Panels can be curved, perforated or micro-perforated to achieve any acoustic performance or supplied with a magnetic whiteboard surface. The panels have a high density and high impact resistance, making them particularly suitable for areas of high traffic.

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8 www.knauf.co.uk kd@web-response.co.uk ( 01795 424499

The Knauf Vinova solutions for walls and ceilings provide complete design freedom

The lacquered and wood veneer boards can be bent to a radius of up to 300mm

Public Sector Build Journal

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ENVIROGRAF Fire Protection for all types of Ceilings Floors, Walls & Ceilings Focus ®

PASSIVE FIRE PREVENTION PRODUCTS

Tested to BS476 Parts 20, 21, 22, 23 (1987) ● 1 hour fire resistant

● Thickness 40mm, sound resistant, tested to BS EN ISO 140 Part 4 for airborne sound reduction mean result Dntw 65 dB.

Suspended Ceiling Barrier with Acoustic Downlighter Cover

● Thermal conductivity U value 0.27W/m2K

● Easy and quick to apply, no special clothing or gloves required. Non fibrous, can be used in sterile areas, Hospitals, computer rooms, etc.

The HW System (Product 42) offers a range of clear, coloured or white coatings designed to upgrade new and existing timber substrates, offering up to 30 or 60 minutes fire protection meeting UK and European Fire Regulations.

30 & 60 minutes Fire Protection Coating for timber substrates

HW System Tested to : BS476: Part 6&7 — Class 0 & 1 Classification BS476: Part 20/22:1987 — 60 minutes EN 1364—1:1999 — 66 minutes EN 13823:2002 ‘Single Burn Item’ EN 11925—2:2002 ‘Ignitability’

SBI:B/s1/d0

BS476 Part 21/22 - 66 minutes in EU

BS476 Part 21/22

EN13501-1:2002

EN14135

BS EN1634/1 2000

BS EN1363/1/1999

Upgrading plasterboard, lath-and-plaster and concrete ceilings and walls

EP/CP (Product 105) is a white or coloured aqueous dispersion coating, offering protection to plasterboard and lath-and-plaster ceilings and walls of various thicknesses, and concrete. It develops a microporous intumescent layer with a smooth decorative finish.

When attacked by fire, the intumescent material protects the coated area’s integrity and insulation for a period in excess of one hour.

EP/CP tested to : BS476 Part 20,22,23 (1987) on 9mm plasterboard

71min insulation and integrity

BS476 Part 21 (1987) on 12½mm plasterboard beneath a loaded timber floor

61 min insulation, integrity and load-bearing capacity

BS476 Part 21 (1987) on loadbearing lath-and-plaster ceiling BS476 Part 20 Carried out at Warrington Test House to exact ceiling structure as St Pancras Chambers

www.envirograf.com

Tel : 01304 842 555

sales@envirograf.com

Fax : 01304 842 666

61 min insulation, integrity and load-bearing capacity 60 min insulation and integrity

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WIDEST RANGE OF PASSIVE FIRE PREVENTION PRODUCTS

Floors, Walls & Ceilings Focus Due to the nature of the building and its usage, the flooring solution had to be sleek, modern and ‘acoustically beneficial’, while providing a seamless floor which straddled varied substrates, including concrete and timber. To minimise vibrations and enhance acoustic performance, an innovative jackedup concrete floor slab was used to isolate the studio from the rest of the building prior to the application of the flooring materials.

With the initial brief only thought possible by applying a sheet material, the successful application of a pure white Sika ComfortFloor Pro by specialist contractor Industrial Floor Treatments (IFT) not only met the demands of this niche project, but also exceeded them, allowing the designers a minimalist and nofuss vision of the space to be brought to life.

Many still do not realise the scope of flooring systems available to today’s public sector specifiers working on public buildings and offices, schools and leisure facilities.

Sika has flooring systems which have been designed to fulfil an almost endless combination of functional and aesthetic requirements, whilst meeting all industry requirements for mechanical and chemical resistance, impermeability and fire resistance – not also forgetting the strict hygiene standards of the healthcare industry.

Sika takes to the floor Sika recently supplied a high performance, slip-resistant and fast-curing flooring solution for the refurbishment of Hangar 3 at RAF Lossiemouth

When it comes to public sector building projects, the product specification process must strike the right balance between performance and cost. Given the sheer volume of floors a building can contain and the heavy traffic some areas are subjected to, it's essential to arrive at an appropriate flooring solution first time. Here Mark Bushell, Sika's Flooring Product Manager, shares his top tips for flooring specification.

Hangar 3 at RAF Lossiemouth, which is set to become the sole base in Scotland for the RAF’s Typhoon F2 Eurofighters and home of the world-famous Squadron 617 formed in 1943 to carry out the Dambusters raid.

For the 5000m2 main hangar floor, Anderson Specialist Contracting required a coating that would deliver easy clean and anti-slip properties, whilst providing a fast and simple application. Developed to offer an outstanding surface finish and exceptional protection against heavy loading, abrasion and chemical exposure, SikaFloor proved ideal.

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hen floors perform well, they go largely unnoticed, but if they fail it can be with disastrous consequences. Every floor space has a specific set of requirements, from general traffic and mechanical wear, through to fire and chemical resistance, slip resistance, impact resistance and permeability to liquids. Then there is the installation process itself. Is the space in question within a carefully controlled temperature range, or is there a requirement to cure the system to a specific timeframe?

Over the past 40 years Sika’s dedicated flooring research and development teams have developed a wider range of market-leading systems which take into account a whole host of design life, operational requirements, construction joints and installation details.

Meeting the ever changing needs of the built environment, Sika has truly embraced the challenge to offer new-build, maintenance and refurbishment flooring solutions that make economic and ecological sense and are suitable for projects of all sizes and requirements.

Whether a large, heavy duty military hangar or an intimate, sound proof recording studio, the company’s extensive range meets the needs of even the most bespoke flooring demands.

For example, Sika recently supplied a high performance, slip-resistant and fast-curing flooring solution for the refurbishment of

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www.sikaflooring.co.uk enquiries@uk.sika.com ( 0800 112 3863

High performance systems Now complete, the refurbished Hangar 3 once again provides an outstanding environment to house some of the RAF’s most prestigious and valuable aircraft. With the help of our high performance floor system, the aircraft base has a floor befitting of its historical heritage whilst offering long term performance for many more years to come.

At the other scale of the flooring spectrum, Sika has options such as Sika ComfortFloor Pro – a seamless, liquid applied flooring system. This system was recently installed during the creation of an acoustically designed live recording studio within an old Victorian building in Edinburgh, which required a continuous brilliant white flooring system throughout the ground floor.

ComfortFloor Pro, a seamless, liquid applied flooring system, was recently installed during the creation of an acoustically designed live recording studio

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A tailored take on flooring Floors, Walls & Ceilings Focus

From wet and dry slip resistance to acoustic absorption, Itec Contract Floors deliver style, performance and low maintenance.

ORDER SAMPLES

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Ford House Care Home St Neots

With Itec Contract Floors you can bring social housing and residential care facilities a warm, luxurious and inviting floor with no practical drawbacks. Easy to keep clean, water-resistant, durable and safe; Itec Contract Floors are tailored to meet the needs of the most demanding locations, creating a welcoming environment that contributes to a positive environment for all.

Contact Itec Contract Floors today for a free consultation of your flooring requirements.

IVC GROUP

IVC GROUP

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IVC Floor Coverings Super Compact Backing

IVC Floor Coverings Expanded Backing

Tested in accordance with BS 797-2:2002 **Such as healthcare & education, visit www.greenguide.co.uk for more

8 Online Public Sector Build080 Journal Enquiry

0800 032 3970 www.itecfloors.co.uk

Floors, Walls & Ceilings Focus as we felt these areas could be a bit more daring in the design for this particular client.

The client is very happy with the result.”

Meeting design criteria Colleague Bob Bissett added: “The Armstrong products were cost-effective and cover the services, making the office environment more attractive. They met the design criteria set at the outset of the project.”

The refurbishment of the 70,000ft² brickfaced building over four storeys took main contractor Como Group seven months and specialist sub-contractor BPC Interiors three months with an average 14 operatives to install the ceilings.

BPC’s QA/H&S manager Alan Edwards said: “Every project has its challenges and Cofunds was no different. Part of the second floor was occupied throughout the project which required some construction activities to take place out of hours. Due consideration was given to the residents and public who live close to the site and any impact our works could have had on them.

“The Armstrong products used on this project were excellent and the assistance we were given was invaluable, not only because the reps visited site to advise but because they were interested in how the project was progressing throughout and made themselves available to the site team whenever needed.”

Refurb all aboveboard Some 3000m² of Armstrong’s white Ultima MicroLook BE 600 x 600mm tiles in a 6mm Silhouette grid were used in the open office areas

A combination of mineral and metal tiles and canopies from Armstrong Ceilings were specified for the refurbishment of Braintree District Council's former offices in Witham, Essex for their cost-effectiveness, aesthetics and acoustic properties. the break-out areas and cafe to provide interest, acoustics and to take the eye away from areas where we proposed an exposed ceiling.

“They were proposed in the staff areas

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ome 3000m² of Armstrong’s white Ultima MicroLook BE 600 x 600mm tiles in a 6mm Silhouette grid were used in the open office areas while Axiom KE (Knife Edge) canopies with Ultima SL2 planks feature in the reception and corridors, 20 Optima circular canopies in the cafe and break-out areas, and metal Tegular 2 tiles in the kitchen.

The Ultima mineral tiles meet sound absorption Class C while the Optima mineral canopies provide 2.00 sabines of sound absorption per piece as well as 82% recycled content. Both feature 87% light reflectance.

They were specified by architects Swanke Hayden Connell for the redevelopment of former Braintree District Council offices in Witham, Essex, into a new home for the 600 employees of Cofunds, now part of Legal & General.

The brief was to create a cost-efficient, modern and comfortable place of work for Cofunds staff.

Project Leader Angela Sasso said: “A mineral fibre ceiling tile met the cost plan and we chose to upgrade some client-facing areas with the plank system in the reception and corridors. The canopies were used in

8 www.armstrong.co.uk sales-support@armstrong.com  enq 081 ( 0800 371849 *

The brief was to create a cost-efficient, modern and comfortable place of work for Cofunds staff

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Floors, Walls & Ceilings Focus

A series of Mapei systems were chosen to enable fast installation and provide a surface suitable for Birmingham New Street station

Mapei paves the way A complete system of Mapei products has been specified in the flooring build up of new public concourses within Birmingham's New Street Station. The £600m redevelopment scheme will include a new concourse, exterior facade and entrances.

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new granite tiling, finishing off with Mapei Ultracolor Plus; a fast setting and drying flexible grout, featuring anti-efflorescence, water-repellent and anti-mould properties.

Complete flooring solution Within service access and temporary flooring within main station areas, UKS Group Ltd laid approx. 500m2 of Mapei’s resin and cementitious flooring products: Mapei’s two component, solvent free Primer SN provided a key for Ultratop Industrial – a fast setting, smoothing, high abrasion-resistant floorcovering. The surface was then finished using Mapecoat I 600 W and Mapecoat I 620 W. Both epoxy finishing systems provide an opaque anti-dust and oil resistant surface, without altering the natural colour of the floor. The Mapecoat I 620 W was also used for the lift pits in RAL 3016, which were

installed by Birse Rail.

Meanwhile, behind the scenes UKS Group Ltd used Mapei’s chemical and abrasionresistant Mapefloor I 350 SL, installed by Prestec Ltd, to create service tunnels for contractor access.

“The station demanded hard wearing flooring capable of dealing with the 140,000 passengers every day; the owners Network Rail wanted a floor that kept within the vision and aesthetic qualities of a modern, vibrant station. A combination of Grants and UKS Group Ltd installation – and a system of high quality Mapei products – ensured both criteria were met,” commented Steve Price, Building Products Manager at Mapei UK Ltd.

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n behalf of principal contractor – Mace – Grants of Shoreditch and UKS Group Ltd prepared and installed 20,000m2 of new flooring. A series of Mapei systems were chosen to enable fast installation and provide a surface suitable for exceptionally high levels of foot traffic.

Phase 1 refurbishment was completed in April 2013, with overall project completion in 2015, along with further Mapei specifications.

Birmingham New Street is the busiest interchange station outside London, with an average of 31.2 million passenger entries and exits each year. Initially, Grants installed a screed containing Mapei’s Topcem binder; the high performance, fast-drying screed which reduces installation time to 24 hours for ceramic and two days for stone tiling.

Mapei’s fast setting flexible S1 adhesive – Keraquick – was then used to install the

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www.mapei.co.uk info@mapei.co.uk ( 0121 508 6970

LEVATO MONO - porcelain paver system

Floors, Walls & Ceilings Focus

Just a few of the benefits at a glance: • ‘Floating floor’ – installation over single ply membranes • Eternal product - zero maintenance required – offering massive over-life savings • Highly abrasion and stain resistant • Highly slip resistant ; R11 and achieved up to +65 wet in the BS pendulum test • Lightweight – 45kgs per m2 • High load bearing and impact resistance • Timber & stone effects ; 40+ finishes available • Ideal for balconies, roof terraces and piazzas, for both commercial & residential use • Completely non porous • Fire & frost proof • Height-adjustable support from 7mm up to 550mm

The Levato Mono porcelain paver system is the pinnacle of external raised flooring technology; enabling the specification of lightweight, slip resistant and attractive raised flooring solutions, combining incredible technical properties with uncompromising aesthetics; making them the ideal choice for commercial and domestic use alike.

t: 0845 2700 696

e: info@thedecktileco.co.uk

www.thedecktileco.co.uk Online Enquiry 083

Floors, Walls & Ceilings Focus

St Pancras Chambers was awarded Grade 1 listed status in recognition of its importance as an example of high Victorian Gothic architecture

The ultimate surface protection Upgrading the country's oldest buildings to ensure they meet regulations is integral so that they are compliant and remain open for the public to enjoy. Here, fire protective coatings specialist, Envirograf explains how two striking architectural buildings have been able to retain their character thanks to its innovative solutions.

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he St Pancras railway station (Kings Cross) was one of the most stunning architectural achievements of the 19th century. The design was an engineering marvel of the time, and became a world famous architectural site. In May 1865, (while the station was still being constructed), the Midland Railway Company launched a competition for the design of a 150 bed hotel, with eleven architects asked to submit their entries.

One of the architects, Sir George Gilbert Scott (1811-1878), got completely carried away and submitted a grand plan bigger and far more expensive than the original specification. But his bare-faced audacity paid off and he was awarded the contract – although the Directors of the Midland Railway immediately demanded some hefty costcutting measures which included knocking off two floors of office accommodation and one floor level from the hotel.

The Midland Grand soon acquired an

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excellent reputation as an upmarket, 300room hotel, charging 14 shillings (70p) a night in 1879 – only six pence (2.5p) more than the luxurious and famed Langham in Portland Place, W1. The building included many innovative features including hydraulic ‘ascending chambers’, concrete floors, revolving doors and a fireproof floor construction. The Victorian decor was rich, lavish and expensive, with suites of rooms decorated with gold-leafed walls and a blazing fire in every room.

Architectural recognition The hotel managed to prosper until after the First World War, but even the Moroccan coffee house and in-house orchestra couldn’t protect the hotel from the countrywide decline in the hotel trade.

The Midland Grand was taken over by the London, Midland and Scottish Railway in 1922, before closing in 1935 – its facilities were

The original drop Lath & plaster ceiling, coated with Envirograf EP/CP

outdated and it had become too expensive to run and refurbish. Now renamed St Pancras Chambers, the premises settled down to a somewhat less glamorous existence as railway office.

The building survived the bombing raids of the Second World War but found itself threatened with complete demolition in the 1960s. Thankfully, this incredible building was saved from being swept away, and was awarded Grade 1 listed status in recognition of its importance as an example of high Victorian Gothic architecture. In the 1980s, the building failed its fire certificate and was closed down, remaining empty for many years.

St Pancras Chambers have enjoyed extensive restoration work, with London & Continental Railways working with Manhattan Loft Corporation to turn the once-derelict hotel into a 5 star Renaissance Marriott hotel with 244 bedrooms, 2 restaurants, 2 bars, a health and leisure centre, a ballroom, 20 meeting and function rooms, and 67 private apartments and penthouses. During this restoration work a particular problem was identified that required an innovative solution.

Many original lath and plaster ceilings required upgrading to a 60-minute fire rating. These ceilings often included ornate plaster castings dating back to the original construction period and were therefore protected under the Grade 1 rating. These ceilings were also unique in their construction.

The laths were fixed to complex steel beam sections suspended from the concrete floor

Floors, Walls & Ceilings Focus above, so whatever fire protection was to be used it not only needed to be light in weight but also able to offer an insulation barrier that would prevent these metal beams from buckling in heat, which would inevitably cause the ceiling to collapse.

Fire Prevention Products London was approached and after an extensive survey developed a solution perfect for the job. The Envirograf EP/CP coating was specified.

EP/CP is an intumescent coating that expands in a fire offering an excellent insulation quality to the substrate structure above. However, due to the importance of the building project and the

sensitivity of the original features a test was commissioned.

The test house built an exact simulation of the complex ceiling steel structure that also comprised of the lath system. Carried out at Warrington Test House according to the principles of BS 476:Part 20:1987 the test was a total success achieving the 60 minute requirement leading to the Envirograf EP/CP being specified and now used throughout the St Pancras Chambers project playing a crucial role in restoring the original magnificence of one of London’s most important buildings!

Fire integrity The Envirograf team has also had the pleasure of working on the University of Bristol’s Clifton House, a Victorian mansion originally built in 1896 for the Tyndall family.

The aim of the architects working on the

The flat panelled door was upgraded with products 38 and 42

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project was to ensure the building remained in its original style, which was the challenge the company gladly took on.

Through the use of its products 38, 42, AM mastics as well as HW systems, Envirograf was able to give 60 minute fire integrity to the building, without sacrificing its original image.

To keep the appearances and to be able to use upper floors at University of Bristol, the open joists and floor boards were again coated with three coats of HW02/E at 8m² per litre per coat and brown AM mastic between joints which had shrunk over the years, giving 60 minutes integrity, insulation and load bearing.

There have been hundreds of these type of floor structures treated to give the 60/60/60 requirement to BS 476 Part 21 1987.

Doors at the property were also treated with a variety of coatings. The raised and fielded door was upgraded with product 42 (HW02/E and HW03/UV), meanwhile the flat panelled door was upgraded with products 38 and 42.

This was a flat panelled door with beading around the panels. The stiles, rails, and beads – all timber EXCEPT the panels were coated with one coat of HWAP clear primer plus two coats of HW01 white intumescent coating.

The panels were rubbed down and then white firecard was cut to size. A thin coat of Stabond was applied to the panels, then a coating of IA (intumescent adhesive) on both the grey side of the card and the panel of the door. The card was applied to the door and rolled flat. When the adhesive was dry, the whole door was coated with spirit-based coating.

www.envirograf.com sales@envirograf.com ( 01304 842555

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Floors, Walls & Ceilings Focus

Elegance meets defiance

In particular, surfaces had to fulfil a requirement very specific to train station environments: the shade of the finish had to be finely tuned to avoid glare. This is important in order to prevent train drivers

â–ź

Shot-peened steel wall cladding on either side of the foot-walk, columns cladded in shot-peened steel in the background

The Paddington Integrated Project is a comprehensive overhaul of part of one of London's major public transport hubs, which included improvements to London Underground, Network Rail and Transport for London services.

T

o meet both functional efficiency and aesthetic criteria, architects Weston Williamson + Partner specified a high-spec finish for stainless steel surfaces, which is achieved through a process commonly found in the aerospace industry and Formula One racing. That meant a challenge for lead contractor Carillion and metalwork contractor CMF, but a relief for maintenance and cleaning staff – and for train drivers’ eyes!

The revamp of the station, which encompasses part of the mainline railway terminus, the taxi rank and the London Underground Hammersmith & City line platforms, addresses peak-time capacity and access issues, while creating a light, contemporary and functional space to welcome international and national travellers as well as local commuters to London in style. Construction began in October 2011

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and was completed in July 2013.

A material challenge Weston Williamson + Partner designed a bright and airy station building, protected by a glass canopy. When choosing materials for the elegant, almost ethereal composition, the team had to marry practical considerations with their ambitious aesthetic vision.

The new design had to achieve high standards of sustainability, lifetime cost efficiency, functionality and accessibility. With a lifetime that is intended to stretch across a whole century, every single fixture and detail had to be built to last and fit for purpose.

A major specification challenge for main contractor Carillion were the large areas of stainless steel surface that form a key part of the design but had to meet the varying and at times unique demands of a busy station environment.

Outside shot of station building with shotpeened railing on rooftop

Floors, Walls & Ceilings Focus

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tel: 01827 871 871 email: ultrafloor@instarmac.co.uk

An

Brand

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Floors, Walls & Ceilings Focus from being blinded by bright reflections as trains come into the busy station.

In addition to that, any surface finish specified would not only have to look good, but also be long-lasting, scratch-resistant, vandalism-resistant, low-maintenance and cleanable.

The answer to this specification puzzle was found in the aerospace industry, in the form of a specialist surface treatment called shot-peening. Today the finish is increasingly specified for high-spec architectural applications – a recent example is the new Giant’s Causeway visitor centre in Northern Ireland, where stainless steel surfaces are exposed to and have to withstand a salty sea air environment.

Hard-working ceramic beads Shot-peening work-hardens a metal surface by bombarding it with steel, glass or ceramic beads, a high-tech variation of a smithy hitting material with a hammer to compress the surface.

In the case of the new Hammersmith and City line station at Paddington, it was the subtle sheen and the clean and non-marking

Trolley point with posts in a shot-peened and tubular rails in a brush finish

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Shot-peened balusters on railings along steps. Columns cladded in shot-peened steel in the background

surface achieved through shot-peening, that initially sparked the architects’ interest.

Following a consultation with experts at Wheelabrator Impact Finishers, an innovative ceramic shot-peened process was specified, which achieves a particularly high-spec, clean hard-finish. Ceramic media has no carbon content, thereby eliminating the risk of ferrous contamination – a possible source of corrosion.

For decorative shot-peen finishes, that have to look flawless for the long run, Wheelabrator Impact Finishers now recommend ceramic shot-peen media as a standard – to create sustainable building elements and reduce lifetime cost.

Chris Pallot, Business Development Manager for Wheelabrator Impact Finishers, who delivered the shot-peening treatment, explains: “A surface work-hardened through shot-peening is extremely durable and tougher to scratch – an important attribute in the station’s busy thoroughfares and heavy-traffic pedestrian areas. We can also fine-tune the reflectivity of the surface within a spectrum from low to medium – striking a balance between getting light into the station and protecting drivers against glare.

“Applied expertly, shot-peened surfaces do not rust. In contrast to some grained or brushed finishes that can produce undercuts

which trap moisture and can cause corrosion and rust plooms. For the Paddington Integrated Project we used a very special ceramic bead which has no ferrous residues and is completely sterile as far as carbon contamination is concerned. That means we can eliminate the risk of corrosion and guarantee an immaculate finish for decades to come.”

Consistent finish As part of the Paddington Integrated Project, a total 1500m2 of stainless steel surface were processed and delivered between April 2012 and August 2013.

4000 individual (grade 316) stainless steel pieces were shot-peened at Wheelabrator’s facilities in Coventry, some of them up to 3 by 6m in size. They included wall-cladding, skirting, balustrades and station furniture, such as trolley points and signage poles.

Each and every one of these items had to have exactly the right shade and a consistent non-directional pattern.

The main challenge when subjecting high volumes and large areas of steel to a precision process like shot-peening is to ensure an absolutely even and consistent finish without flaws or patches. This can only be achieved in automated environments with absolute process control.

Floors, Walls & Ceilings Focus

Two of the columns cladded in shot-peened steel, shot-peened steel skirting along glass partitions

Chris Pallot adds: “Because the station is built for the long haul, the surface has to be perfect at the point of installation. We are one of the few shot-peening experts in the world who can handle objects of this size and to this specification and deliver a precise, nondirectional surface right across the sheet.

We have been involved in a number of high-profile architecture projects recently, for example the new visitor centre at the Giant’s Causeway or Heatherwick Studio’s vents on Paternoster Square in London, but this one was definitely a challenge. The sheer volume of pieces that had to be processed – there

was no time to get it wrong!”

The result of the team’s effort is now visible throughout the new London Underground station and the Paddington Mainline Station Taxi rank: stainless steel with a soft and elegant lustre, made to last without maintenance – apart from the occasional wash with soap and water.

Thinking about specifying shot-peened surfaces? Beyond the stunning visual effect it creates, shot-peening has a number of immediate advantages – especially compared to coating: • It is durable and highly scratch-resistant • It helps to protect the surface against corrosion • It is easy to maintain and creates a lasting finish that never deteriorates • It provides an even ‘lustre’ finish with medium to low reflectivity

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When specifying shot-peening, a number of factors have to be taken into account, including thickness and type of the material, desired finish, in-situ conditions, as well as usage and maintenance requirements.

www.wheelabratorimpact.com impact@wheelabratorgroup.com  enq 086 ( 01753 215676 8

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As part of the Paddington Integrated Project, a total 1500m2 of stainless steel surface were processed and delivered

Public Sector Build Journal 17

Floors, Walls & Ceilings Focus

F. Ball prescribes Stopgap 1200 Pro

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Following installation of the underlayment, Styccobond F46 was used to adhere the vinyl floorcovering

and minimises the effect of trowel serrations shadowing through the vinyl floorcovering for an aesthetically pleasing finish.

Commenting on Stopgap 1200 Pro, Roy Henderson of A&H Floorcovering Specialists, said: “Stopgap 1200 Pro was an excellent product to work with, and provided us with the speed and ease we were looking for with this challenging installation. The product had excellent self-smoothing properties and produced a professional finish, which was particularly impressive considering the little work it needed – I’d thoroughly recommend it.”

Stopgap 1200 Pro, packaged in a 20kg sack and 5 litre bottle, can be applied ‘unfilled’ to maximum thicknesses of 10mm and, filled with a graded aggregate, in applications of up to 30mm.

8 * 

enq 087

www.f-ball.co.uk mail@f-ball.co.uk ( 01583 361633

The brand new high performance smoothing underlayment, Stopgap 1200 Pro from F. Ball and Co, has provided the perfect solution during the recent refurbishment of Dumfries and Galloway hospital pharmacy.

T

he smoothing underlayment, which is the latest addition to the company’s high performance Stopgap range, was specified to provide a professional flooring solution for a residuecontaminated subfloor creating a durable, high quality floor finish, without the need for priming or mechanical removal of the residue.

A solid bond On removal of the old floorcovering and the results of a moisture measurement test concluding the subfloor was suitably dry to proceed, contractors at A&H Floorcovering Specialists discovered the surface was contaminated with asbestos tile adhesive (ATA). This restricted their ability to mechanically prepare the subfloor. Proving an ideal solution to the problem, contractors were able to completely cover the firmly bonded adhesive with an application of Stopgap 1200 Pro. The innovative smoothing underlayment from F. Ball has been formulated for direct application over waterproof surface membranes and old

18 Public Sector Build Journal

adhesive residues, without the need for priming, and offers a cost effective, time saving solution for the flooring contractor.

A 3-4mm layer of Stopgap 1200 Pro was applied over the 160m2 area. Utilising the latest cement technology, the latexfree smoothing underlayment achieves fast setting and drying times for preparing sound internal subfloors. With a working time of 20 minutes, and a walk on time of just 60 minutes, the pharmacy was ready to receive its new vinyl floorcovering after only four hours.

Suitable for a variety of flooring installations, Stopgap 1200 Pro can be used over a wide range of subfloor types, such as sand/cement screeds, concrete, terrazzo, asphalt and ceramic tiles. It is also suitable for patch filling timber floors prior to overlaying with plywood.

Speed and ease Following installation of the underlayment, Styccobond F46 was used to adhere the vinyl floorcovering. This solvent free, pressure sensitive adhesive has a high-bond strength

Utilising the latest cement technology, the latex-free smoothing underlayment achieves fast setting and drying times

Online Enquiry 088

Floors, Walls & Ceilings Focus

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