ISSUE 4 | AUTUMN 2021
LIGHT STEEL FRAMING MAGAZINE THE L ATEST IN LIGHT STEEL FR AMING TECHNOLOGY DEVELOPMENT
HADLEYFRAME – AN ISLAND FIRST FOR JERSEY
LIGHT STEEL FRAMING MAGAZINE
P20 LATEST PRODUCT INNOVATIONS Taking factory prefabrication to another level
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OFFSITE AWARDS BEST USE OF STEEL
THINKING OF SHIFTING TO STEEL MANUFACTURING?
Unique and innovative project but challenging to construct
Top tips and advice to help make a seamless and profitable transition
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A DIFFERENT WAY OF THINKING BRITISH OFFSITE’S HYBRID SOLUTIONS ARE DESIGNED TO EASE YOUR TRANSITION FROM TRADITIONAL TO MODERN METHODS OF CONSTRUCTION, WHETHER YOU’RE SEEKING AN EVOLUTION OF REVOLUTION IN HOW YOU BUILD. Developers before we became manufacturers, we: • Understand the needs and challenges of the design and construction industry • Reduce the risks and delays in construction to deliver your occupiable properties faster • Consolidate the work of up to five trades in our flexible UNI System • Produce the architecture you need with precision, in the most efficient way possible
Champions of precision, born to build Second factory arriving 2022 www.britishoffsite.com info@britishoffsite.com
Think British Offsite from the offset
WELCOME
PUBLISHING
Welcome to the latest issue of Light Steel Framing Magazine providing some news and views from the industry and published in partnership with the Light Steel Frame Association (LSFA) – an organisation set up to support the overall objectives and growth of the sector.
FRONT COVER: Hadley Group – Plaisant Place PRINTED ON: PEFC 16-33-576 paper stock by Buxton Press
PUBLISHER: Light Steel Framing Magazine is produced in partnership with the Light Steel Frame Association and published by Radar Communications: ©Radar Communications Ltd. Radar Communications Ltd, 101 Longden Road, Shrewsbury, Shropshire, SY3 9PS T: 01743 290001 www.radar-communications.co.uk SUBSCRIBE TO RECEIVE: www.lightsteelframingmagazine.co.uk ADVERTISING ENQUIRIES PLEASE CONTACT: Julie Williams // T: 01743 290001 E: julie.williams@radar-communications.co.uk SEND US YOUR NEWS: T: 01743 290001 E: info@lsf-association.co.uk FOR ENQUIRIES PLEASE CONTACT: E: info@lsf-association.co.uk DISCLAIMER: The content of Light Steel Framing Magazine does not necessarily reflect the views of the editor or publishers and are the views of its contributors and advertisers. The digital edition may include hyperlinks to third-party content, advertising, or websites, provided for the sake of convenience and interest. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any advertising or products available from external sources. No part of this publication may be reproduced or stored in a retrieval system without the written consent of the publishers. All rights reserved.
As the construction industry continues to recover and we are able to once again meet face to face, there is an air of positivity within our industry. The sector is firmly behind the mantra to ‘Build Back Better’ and in this issue we feature a wealth of product innovations in light steel framing which take factory prefabrication to another level to enhance building programmes, productivity and performance. As an indicator to support this optimism, the recent Offsite Expo exhibition and conference clearly demonstrated the unprecedented levels of progression in our industry. The sector was out in force, and I was fortunate to chair one of the light steel frame CPD Accredited Masterclass sessions. Interest in recent advancements was exceptional. I firmly believe we have now reached a turning point and the questions following the presentations demonstrated that constructional professionals ‘get it’. They were very well informed and showed excellent levels of understanding, now that the benefits of using light steel frame are valued, we have to get down to the detail. The LSFA’s website library contains in-depth information freely available to download including the Specification and Engineering Guide for Light Steel Frame Construction compiled by technical and manufacturing members. This guide outlines design opportunities, fire safety, performance in construction and in use together with the different types of systems, applications, and interfaces of light steel frame. Most importantly, the Specification and Engineering Guide outlines the sustainability benefits of steel that are not widely understood. I must also mention the Offsite Construction Awards that took place at Offsite Expo. The Best Use of Steel was a fiercely contested category featuring pioneering projects. For a more comprehensive look at the finalists and the ultimate winner, turn to page 27. Finally, we are interested in your light steel frame news, so if you have a groundbreaking development or innovation you would like to showcase – then we would like to hear from you.
Mike Fairey Chairman - Light Steel Frame Association Director - Fusion Building Systems info@lsf-association.co.uk To Download the Light Steel Frame Association’s Specification and Engineering Guide go to: www.lsf-association.co.uk/library
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Build with steel, the Howick way Whether you are expanding your offsite offering or switching to modular building for the first time, there is a lot to consider. And we should know. At Howick, we have been innovating in the fast-build construction space for decades. Our precision light gauge steel (LGS) roll-forming technology brings accuracy, speed and performance that is trusted by smart construction businesses throughout the UK and the world.
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In this issue...
CONTENTS
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HadleyFRAME – An Island First For Jersey
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Industry News
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Product Innovation
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Offsite Expo and Offsite Awards
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Delivered by Hadley Group, Plaisant Place is an incredible scheme boasting 21 apartments and ground floor development tailored specifically for Age Concern’s new headquarters on the island.
Highlighting the latest construction industry initiatives, project developments and building technology innovations in the UK light steel framing sector.
Leading rainscreen and facade manufacturer BTS Fabrications has brought a pioneering complete ‘through wall’ solution to market and British Offsite deliver high levels of offsite added value with their UNI Panel system.
The recent Offsite Expo and co-located Offsite Awards clearly demonstrated the unprecedented levels of progression in our industry. With the light steel frame sector out in force, we report on some of the key highlights.
Pioneering A New SFS Approach EOS has taken factory prefabrication and preassembly to another level with the launch of their PAF system – delivering predictable performance in one unitised solution.
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Premier Inn’s Flagship Oxford Hotel Employs LSF
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Technical Developments Affecting Light Steel Framing
Allison Pike Partnership reflect on their collaboration to deliver a complex design solution for this £1.2m hotel in a sensitive historic location.
Andrew Way, Associate Director at the Steel Construction Institute provides an update on two recent technical developments affecting the light steel framing sector.
Driving growth and supporting the objectives of the light steel frame industry
JOIN US TODAY!
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COVER STORY HADLEY GROUP
HADLEYFRAME – AN ISLAND FIRST FOR JERSEY
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PLAISANT PLACE IS THE CULMINATION OF THE COLLABORATION OF STEEL FRAMING EXPERTS, HADLEY GROUP, SOCIAL HOUSING SPECIALIST ANDIUM HOMES, LOCAL JERSEY CONSTRUCTION FIRM NORMANS, PRINCIPAL CONTRACTOR ROK AND PAGE ARCHITECTS. THIS INCREDIBLE SCHEME BOASTS 21 APARTMENTS AND A GROUND FLOOR DEVELOPMENT TAILORED SPECIFICALLY FOR AGE CONCERN’S NEW HEADQUARTERS ON THE ISLAND.
The project has provided a wealth of benefits to Jersey, developing new skills locally, proving the advantages of steel frame construction and replacing a dated but essential community facility. “The space in our building was no longer fit for purpose, as the facilities were spread out over three floors, with far too many stairs, slopes and a temperamental lift – none of which are conducive to offering a wide range of activities for older people,” said Paul Simmond, Senior Manager for Age Concern. Plaisant Place was designed by Page Architects to offer maximum flexibility, allowing Age Concern to host a variety of events all on one level to increase accessibility. A large function room will hold dances, classes, and a multitude
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of social activities, with events designed to promote mental and physical health held in two additional rooms. Alongside delivering a new headquarters for Age Concern in Jersey, the project provided local construction firm Normans with an opportunity to develop a new skill set which they can take forward on the island. Steve Chesters, Commercial Director at Hadley Group explained: “We are really keen to work with Island businesses to develop their team’s skill sets so that future builds can be carried out by an entirely local workforce.” The Hadley Steel Framing team worked closely with the assembly personnel from local firm Normans to support construction of the 401 panels and roof cassettes. “It’s a really innovative
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and high-speed construction method and one which is a game-changer for the Island,” explained Simon Chard, Managing Director of Normans. Principal contractor ROK, were equally as excited by the potential of the collaboration “We are always looking for new, innovative and forward-thinking building processes so we really valued the opportunity to work closely with Hadley Steel Frame and Normans on this development,” said ROK Project Manager Richard Blackman. “We engaged with the Hadley team and Normans very early before construction started to ensure that we fully understood the system and processes involved. The Hadley frame was a great solution which eradicated many of the usual issues and enabled us to meet the very keen project timescale.”
COVER STORY HADLEY GROUP
The HadleyFRAME System For anyone watching the construction the speed the building went up would have been unmissable. A testament to the HadleyFRAME system and Normans’ adoption of the process – the main structure was assembled in just 10 weeks. The HadleyFRAME offsite system is a panelised fully loadbearing structural solution. Ideally the structure is installed on a reinforced concrete slab or transfer structure, but the high strength to weight ratio and relative weight saving in the system means it can also be used on top of existing structures. The external walls are provided as panels made from 100mm galvanised steel studs at 600mm centres (gauge of steel for the studs varies with loads). The external wall panels also arrive on site preboarded with an external sheathing board and vapour barrier factory applied. Structural efficiency gains are made through the HadleyFRAME system being deployed as a whole, utilising internal loadbearing wall panels in the design. Wall spans are kept to a minimum, with only structural walls included to reduce unnecessary costs. Internal walls are panelised with 100mm studs and do not include linings. In addition, the panels are used to form the lift shaft and staircore. The lift shaft is designed to the manufacturer's specifications and includes a lifting beam (tested by others) with plates or rails to take the lifting gear. Stairs are hot rolled steel with the pans infilled with either screed or dry screed board. A comprehensive approach is at the heart of HadleyFRAME’s structural stability, achieved by bracing being distributed throughout the wall panels rather than using hot rolled braced bays or relying on the core. Most internal and external walls include bracing which is a 1.5mm flat strap used as a cross brace to the face of the panel. The most popular option for intermediate floor is a 150mm composite deck, with deeper decks available for larger spans or loads. Joisted cassettes can be used, as an intermediate floor, typically formed
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04 with 200mm of galvanised steel joists and an 18mm ply deck for stability and access. The joisted cassette is a lighter option if structure weigh is an issue. However, for greater fire and acoustic performance many clients specify a composite concrete deck in lieu of the joisted cassette which relies on the linings for its performance. A roof formed from 200mm joisted cassettes is the standard option, saving weight over the composite alternative. A straightforward and cost-effective flat roof is the most common option. Simple falls can be included in the design. Traditional pitched roofs are also offered. Full detailing and design are included by the Hadley UK in-house experts. IFC models are provided during the design phase for coordination with other trades. This method of construction offers significant efficiencies reducing timescales by 20% over traditional construction methods, requiring far fewer deliveries to a central restricted location and significantly reducing people on site who normally fulfil traditional trades.
The advantage of training local labour was not just in upskilling. It meant the common shipping delays experienced on the island could be managed as components could be delivered well ahead of programme and stored efficiently ready for scheduled assembly. Normans then panelised the components with Hadley’s training with the work certified under their FPC certification, producing offsite prepanelised sections with sheathing board on the external walls. The project has been a resounding success with the positive collaboration demonstrating the advanced method of construction improves productivity and reduces environmental impact while delivering a high-quality result. Source: Andium Homes and Jersey Evening Post
Contact the structural team to find out more on sales@hadleysteelframing.com
For more information visit: www.hadleygroup.com IMAGES 01-04. Plaisant Place has provided a wealth of benefits and an essential community facility for Jersey.
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INDUSTRY NEWS
SCI TO HOLD ANNUAL EVENT ONLINE
DAVID ELLISON JOINS FUSION BUILDING SYSTEMS
The Steel Construction Institute’s (SCI) Annual Event will be online this year and is open to both SCI Members and non-members to attend. The key focus will be on ‘net zero’ solutions and will report on the various decarbonisation initiatives that the sector in particular the steel producers have embarked upon. SCI will present on some new initiatives which have been identified to help the UK Steel construction sector meet its needs, including the launch or Trimble Tedds Modules aimed at designers, and their new Thermal Modelling service. Presentations will be made by Will Arnold, Institution of Structural Engineers; Walter Swann, ArcelorMittal; Michael Sansom, SCI; Sara Halliday, Severfield Plc; Stuart Campbell, Trimble; Callum Heavens, SCI and Constantinos Kyprianou, SCI. The event will on Tuesday 09 November between 10:30 – 14:00 and will be chaired by Graham Couchman, CEO, SCI. Register for this event at: www.steel-sci.com
MAKING THE HEADLINES We are interested in your light steel frame news, so if you have a groundbreaking development or innovation you would like to showcase – then we would like to hear from you. SEND YOUR NEWS TO:
info@lsf-association.co.uk
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David Ellison was recently appointed Head of Sales & Business Development at Fusion Building Systems, the leading manufacturer of offsite light steel frame panelised superstructures in the UK. With over 20 years’ experience in the volumetric modular and loadbearing light steel frame industry, David has an extensive network of contacts and connections to further grow the business at Fusion. David has become recognised as an industry expert, due to his knowledge with offsite manufacturing and is now advising Fusion clients on the benefits of light steel frame construction, how to enhance cost effectiveness and accelerate the programme of new build schemes. Mike Fairey, Fusion Building Systems Director said: “I have always admired David’s infectious enthusiasm for offsite construction and his excellent record in business growth through providing the proactive support services required to assist clients on their journey towards the successful adoption of a light steel frame as an optimum MMC solution. “David will lead our business development team on our quest for significant growth over the next three years. In addition, he will play a key role in the continued expansion of the Fusion Scope of Works, continually looking to improve our DfMA (Designed for Manufacture and Assembly) strategy and the optimisation of our panelised ‘Smart Modular’ approach.” Fusion Building Systems is an offsite designer, engineer, manufacturer and installer of light steel frame panelised superstructures. Over the last 20 years, Fusion has delivered more light steel residential structures than any other producer in Europe. Commenting on his new role David said, “There is tremendous knowledge and experience within this team especially if we are brought in at the design and early build stage. I believe we can really help clients to be more cost-effective and efficient with relevant new projects especially around multi-storey apartment blocks used in residential housing or the education sector.” Source: www.fusionbuild.com
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INDUSTRY NEWS
ETEX ACQUIRES SIGMAT UK LIGHT STEEL FRAMING MARKET LEADER
Etex recently announced the acquisition of Sigmat, a market leader in the UK light steel frame (LSF) sector. This complements the purchase of Irish design and engineering consultancy firm Evolusion Innovation and Irish light steel frame provider Horizon Offsite.
Since 2016, Sigmat has been backed by UK midmarket private equity firm LDC whose investment has supported expansion of R&D capabilities, geographical coverage as well as development of state-of-the-art production facilities in Yorkshire. This transaction marks an exit for LDC.
Since its inception in 2001, Sigmat has rapidly grown into a prominent manufacturer of cold-rolled steel components and panelised structural steel frames. With headquartered in Leeds, Sigmat was one of the country’s first fully integrated offsite construction companies, offering design, engineering, manufacturing, assembly and installation services to its customers.
Mark Eburne, CEO of Sigmat said: “We have worked hard to develop innovative, cutting-edge products, bolster our UK presence and keep the environment at the heart of our business strategy. In LDC we have had a supportive investor and have grown through working in partnership with our customers to help them leverage the benefits of offsite solutions. We are now excited to look ahead as part of Etex, which we believe creates significant opportunities to take Sigmat to the next level.”
Employing a dedicated workforce of around 235 people, the company serves a broad and varied customer base, including blue chip clients in construction market sectors such as residential, education, leisure and senior living. Research, development and innovation are at the heart of Sigmat’s business approach, with the company focussing on the design of unique patented and highly technical products. By harnessing the power of recyclable steel combined with world class design, Sigmat builds structures that have minimum impact on the environment.
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Strengthening Etex New Ways Division Etex’s vision is to be at the forefront of the industrial, digital and sustainable transformation of the construction industry, particularly in the area of offsite building solutions. In 2020, Etex launched the New Ways division and realised several acquisitions in Europe and Latin America. Those efforts are now reinforced with the acquisition of Sigmat in the UK.
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By acquiring Sigmat, Etex’s New Ways expands its light steel frame and offsite solutions footprint in the UK. This strategic acquisition, together with its existing UK-based EOS business, not only firmly establishes the division as a major force in the light steel frame sector. Paul Van Oyen, CEO of Etex said: “The emerging market for offsite solutions is capable of fulfilling numerous global needs. With New Ways specialising in these technologies, Etex seeks to bring high-quality, sustainable and affordable living spaces to people around the globe – and the acquisition of Sigmat only adds to our capability to put our ambitions into practice.” Sigmat’s experienced management team will remain on board as part of New Ways, bringing in valuable expertise, market intelligence and business insights. This will allow the Etex division to fine-tune and consolidate its organisational structure in the UK. Source: www.etexgroup.com
INDUSTRY NEWS
STEEL INDUSTRY SETS ITS PATH TO NET-ZERO Some of the world’s leading steelmakers have produced a set of clear recommendations for adopting science-based targets (SBTs) for the industry’s road to net-zero in a report titled “The Net-Zero Steel Pathway Methodology Project: Final Report and Recommendations” (NZSPMP report) published in July 2021. The report, produced by an international group of major steelmakers together with the World Steel Association and ResponsibleSteel, sets out a framework for developing robust guidance for those in the sector who wish to make a realistic and credible commitment to the Paris Agreement, with a net-zero or ‘science-based target’. The key recommendations for greenhouse gas (GHG) emissions reduction targets are:
1: Differentiate between primary and secondary steel 2: Set a consistent scope and system boundary 3: Establish a consistent steel sector budget and trajectory 4: Acknowledge the GHG emissions reduction from using co-products made by the steel industry 5: Integrate the influence of regulatory policy when setting a science-based target 6: Leverage existing standards and methods into a dedicated steel sector decarbonisation approach for more consistent target setting 7: Develop unambiguous guidance for companies making different types of steel products Fifteen of the world’s largest steelmakers, including ArcelorMittal, GFG Alliance, Tata Steel and BlueScope Steel, contributed to the report over the last year in order to produce these recommendations which will help the steel industry set ambitious net-zero carbon targets. The recommendations set out in the NZSPMP report are a significant step to help guide steelmakers to become more consistent in how they measure and set company level GHG emissions reduction targets.
To download the report, go to: netzerosteelpathwayproject.com
The LIGHT STEEL FRAME ASSOCIATION has been established to influence legislation, regulation and to support the overall objectives and growth of the steel framing sector.
LSFA MEMBERSHIP PROVIDES: Forward thinking with an inclusive culture – the Light Steel Frame Association unifies and unites construction professionals through: •
Collaboration, joint venture and networking opportunities
• Valuable industry intel and gaining direct access to the UK’s leading manufacturers •
Opportunity to explore project parameters by joining the Design for Manufacture and Assembly debate
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Key industry contacts and business development opportunities
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Light steel frame insight and technical offsite manufacturing expertise
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Access to the latest research and information sharing with industry pioneers
To be part of something bigger, contact us today… Email: Info@lsf-association.co.uk WWW.LSF-ASSOCIATION.CO.UK
ADVERTORIAL
TRIED AND TESTED NON-COMBUSTIBLE STRUCTURAL SOLUTION With over 20 years’ experience in offsite solutions, Fusion Building Systems has developed FusionX – a non-combustible light steel frame system for all building types. Using the team’s extensive industry knowledge, FusionX was created in response to changes in Building Regulations and is certified up to 10-storeys and can form part of a structure up to 14-storeys. Commercial Performance FusionX offers a cost-effective rapid build solution, whilst ensuring high levels of quality. Produced under well-managed factory conditions, FusionX provides a basis for a precise installation, speeding up the construction process whilst reducing health and safety risks and increasing productivity on site.
Fusion_Advert_W190mm_x_H127mm.indd 1
Manufactured from cold rolled steel, FusionX is a durable, dimensionally stable material with a better strength to weight ratio than concrete. The benefits of FusionX are impressive. Reliability is excellent when compared to other construction materials. Steel does not shrink, rot, warp, crack or creep, it does not expand or contract with moisture content. FusionX is quick and easy to install on site. Fire Performance FusionX has undergone independent testing and a range of fire test performance data has been achieved demonstrating 60, 90 and 120 minutes compliance. More details are available in the Fusion Fire Specification Guide: www.fusionbuild.com/downloads
Made up of a combination of fire-tested component parts to create a fully non-combustible wall, FusionX brings precision by offsite manufacturing and provides endless benefits to construction projects, including on site efficiencies and cost certainty. Having gained approval from NHBC Accepts, LABC Warranty and Premier Guarantee, I am confident this will lead to builders opting for FusionX as a tried and tested offsite method of construction.”
Thermal Performance Designed to meet the demands of modern thermal performance, full U-value data for FusionX is also available in the downloads section of www.fusionbuild.com
FusionX has been developed by a company which has delivered more light steel residential structures than any other producer in the UK. Fusion provides a full collaboration process from project concept stages covering design, engineering and pre-construction support ensuring clients have the right layout options to maximise efficiencies and resources on projects and then through our internal manufacturing facility and to site where Fusion Site management oversee and sign off our builds.
Fusion Director Mike Fairey commented, “FusionX is a result of our teams hard work and excellent product testing legacy over some 21 years.
If you have a project and think FusionX could provide the solution, talk to the experts at Fusion on 01604 490540 or visit www.fusionbuild.com
11/10/2021 18:20
INDUSTRY NEWS
INTELLIGENT STEEL SOLUTIONS APPOINTS NEW MD
Gus Houliston has been appointed Managing Director of Intelligent Steel Solutions to drive strategic development of the business as it seeks to increase its prominence within the loadbearing and SFS markets. Driving long-term growth, Houliston will take Intelligent Steel forward as it expands into healthcare and student accommodation markets, with its sights set on higher volume light steel frame projects. He will also be prioritising component supply for the modular sector due to an increase in demand. Houliston has over 25 years’ experience in the construction industry in several managing and operations director positions. He spent 10 years at LNT Construction as Managing Director, where he played a pivotal role in introducing LSF to the care and assisted living market. Other notable successes
include working on 22 Bishopsgate during his time at Severfield and setting up the industrial division at Midgard, securing the business’s first PCSA for a new cruise terminal project in Southampton. On his appointment, Houliston commented: “We have a strong pipeline of work and the capability to really take a hold of the market and to grow newly acquired SFS, loadbearing and modular LSF business. LSF has a significant role to play in helping to decarbonise the structural fabric of new and existing buildings. It lends itself to MMC, which can help the UK build much quicker and to higher quality, with enhanced sustainability and health and safety credentials. I am looking forward to leading the business in our forward journey.” Source: www.intelligentsteel.com
PLANNING GRANTED FOR LSF EXTRA CARE HOUSING SCHEME
Anwyl Partnerships is moving forward with delivery of its latest land-led development on the Wirral under a joint application with ‘NHS Property Services’. Specialists in the provision of residential land and build developments, Anwyl has partnered with Magenta Living to deliver the £8.5million project, which is set to
begin December this year, following a unanimous vote from Wirral Council to grant full planning permission. Following negotiations, Anwyl has chosen Mansell Building Solutions as its preferred specialist partner to deliver the light steel framing system for this scheme, with the potential for delivery of the follow-on fire protection and drylining works.
The extra care housing scheme on Greenheys Road in Wallasey, Wirral, comprises 53 apartments and will help to fulfil a much-needed gap in high quality, affordable extra care accommodation in the Borough, whilst making use of the brownfield site, which currently houses two former NHS buildings which were recently taken out of use. Source: www.mansellbuild.co.uk
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INDUSTRY NEWS
DESIGN CONSULTANCY THAT LIKES TO ‘GIVE SOMETHING BACK’ Design and Consultancy Solutions (DACS) use the very latest in 3D construction modelling software, Tekla Structures together with models created with Tekla BIM software to produce the accurate, reliable and detailed information needed for successful Building Information Modelling (BIM) and construction execution for high and medium rise loadbearing structures and light steel frame infill systems. DACS are not only a light steel frame design company that offer a digital services using cutting edge 3D modelling software, working in a real time digital modelling environment – as a team they like to give something back. As clearly demonstrated when the team took part in the Great North Run 2021 raising over £3,000 for a local North
East charity close to their hearts. Heel & Toe supports children with Cerebral Palsy and other physical disabilities and is the only charity in the region to offer free conductive education and they rely on charitable donations as they receive no government funding.
our clients and supply chain partners for their donations and those who took part from DACS and team Frameclad with a special shout out to Adam who suffered with COVID with less than a month to go before the Great North Run. Well done to all – let’s do our bit and help out.”
Nik Teagle Director of DACS commented: “We would like to thank
www.dacs-ltd.com
Leading Design Consultants for the Light Steel Framing sector CONTACT US
01642 686 556 info@dacs-ltd.com
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INDUSTRY NEWS
RIBA PUBLISHES DESIGN FOR MANUFACTURE AND ASSEMBLY GUIDANCE
The Royal Institute of British Architects (RIBA) has published a new guide for practices looking to design projects to be built offsite. The Design for Manufacture and Assembly (DfMA) Report and Overlay provides guidance on implementing seven categories of Modern Methods of Construction through each RIBA Plan of Work stage First published in 2016, the Design for Manufacture and Assembly (DfMA) Overlay to the RIBA Plan of Work was quickly embedded as a project management guide when implementing modern methods of construction (MMC). The new edition is based on five years of evolution, including the definition of seven categories of Modern Methods of Construction (MMC), and aligns with the RIBA Plan of Work 2020. The supporting report sets out drivers of change towards a manufacturing mindset as well as explaining why a DfMA approach must be adopted as a default to fulfil the outcomes our industry needs to achieve.
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As much as DfMA is a technical process, it is also a philosophy that should be seen as an extension or evolution of the designer’s ordinary way of working – and does not alter the fundamentals of good design and production, which have always been about getting the best possible outcomes for clients and communities. The DfMA Overlay to the RIBA Plan of Work aims to dispel the myth that DfMA is a barrier to great architecture or reserved just for a few new build sectoral building types. As the case studies in the report highlight, DfMA can produce extraordinary, awardwinning architecture, with few limits on where it can be applied. It is relevant to all kinds of projects, including small projects and work on existing buildings. Simon Allford, RIBA President and Executive Director, Head of Design Studio, Allford Hall Monaghan Morris said: "Architects can be seen as the natural custodians of good design and have the potential to help lead in the adoption of DfMA. Not least as we understand that successful implementation lies in collaboration at
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the boundaries between traditional disciplines and in developing hybrid solutions that draw on a wide range of different bodies of knowledge." The overlay has been produced by a group of industry experts and has been supported by Akerlof, Buildoffsite, Kier, Supply Chain Management School and UK Research and Innovation, and endorsed by Mark Farmer, Founder of Cast Consultancy and UK Government MMC Champion for Homebuilding Source: Royal Institute of British Architects (RIBA) To download the DfMA Overlay to the RIBA Plan of Work go to the Knowledge and Resources at: www.architecture.com
INDUSTRY NEWS
O’DWYER STEEL ANNOUNCES SIGNIFICANT GROWTH O’Dwyer Steel recognised as a leading hot rolled steel supplier to the offsite sector has announced significant growth in its Offsite Manufacturing Division. With over 60 years of experience in the traditional fabrication market, including 10 years fabrication in offsite, this puts O’Dwyers in a position to provide a fast and reliable fabrication service to its offsite manufacturing partners. Completion of hot rolled fabrication for over 200 offsite projects has positioned O’Dwyer Steel at the forefront of the industry. Charles Walsh Head of the O’Dwyer Steel Offsite Division believes their growth and success is credited to the experienced team at O’Dwyer Steel who are heavily focused on delivering a high-quality hot rolled steel product.
quality, state-of-the-art machinery and technical expertise available at O’Dwyer steel are the key elements to the success.
The manufacturing facility at O’Dwyer Steel is set up to respond to the rapid nature of modern methods of construction. Matthew Ryan Managing Director points out that O’Dwyer Steel are established as a key fabrication partner in the supply chain for offsite manufacturing industry. Our fabrication team have adapted their traditional fabrication experience to meet the challenges of fabrication for offsite manufacturing. We are heavily focused on delivering a high-quality product within the refined tolerances required for modern method of construction. Adrian Crosse Head of Estimating Department emphasises the consistent
O’Dwyers have identified further potential for growth of its offsite division. Contracts Director Richard Walsh and O’Dwyers UK Business Development Manager Alan Wildsmith are keenVillage to highlight the potential of Dundrum, Co. for Tipperary, Irelan offsite clients to draw on the wide base of in-house experience and professional expertise that can be provided by the team at O’Dwyer Steel.
www.odwyersteel.ie Village of Dundrum, Co. Tipperary, Ireland
Village of Dundrum, Co. Tipperary, Ireland
One of Ireland’s & the U.K’s leading suppliers of CE certified structural steel Village of Dundrum, Co. Tipperary, Ireland
Village of Dundrum, Co. Tipperary, Ireland
Stock yard
Village of Dundrum, Co. Tipperary, Ireland
Over 1000 tonnes held in stock
Stock yard
Fabrication & Weldin
Capacity to produce 1000 f per week. (80 to 200 tonne
2.5 Acres Storage Area CNC Machinery hall Fabrication & Welding Workshop Gietart Shotblaster Capacity to produce 1000 fabrications
Over 1000 tonnes held in stock
2.No Ficep endeavour saw Peddinghaus plate process Peddinghaus angle master Gietart Shotblaster 2.No Ficep endeavour saw and 6m drill line x 2m flat bed plasma b
per week. (80 to 200 tonnes) Heated Paint Shop
2.5 Acres Storage Area Stock yard
Over 1000 tonnes held in stock
2.5 Acres Storage Area Heated Paint Shop Stores Admin & Design Office
Stores
Fabrication & Welding Workshop
Heated Paint Shop
Capacity to produce 1000 fabrications per week. (80 to 200 tonnes)
CNC Machinery hall
Gietart Shotblaster 2.No Ficep endeavour saw and drill line Peddinghaus plate processing Peddinghaus angle master machine 6m x 2m flat bed plasma bed
Stores
Stock yard
Peddinghaus plate processing Admin & Design Office Peddinghaus angle master machine
Admin & Design Office
6m x 2m flat bed plasma bed
Fabrication & Welding Workshop
Over 1000 tonnes held in stock
Capacity to produce 1000 fabrications per week. (80 to 200 tonnes) Stock yard
Fabrication & Welding Workshop
2.5 Acres Storage Area
Over 1000 tonnes held in stock
Heated Paint Shop
2.5 Acres Storage Area CNC Machinery hall line 2.No Ficep endeavour saw and drill
Stock Call Usyard at: (+353) 62 71102 Fabrication & Welding Workshop
www.odwyersteel.ie 2.5 Acres Storage Area CNC Machinery hall
Gietart Shotblaster 2.No Ficep endeavour saw and drill line
Gietart Shotblaster
Gietart Shotblaster
Admin & Design Office
Over 1000 tonnes to produce 1000 fabrications email: info@dwyersteel.ie Capacity held in stock per week. (80 to 200 tonnes)
Capacity to produce 1000 fabrications CNC Machinery hall per week. (80 to 200 tonnes)
plate2.No processing Ficep endeavour saw and drill line HeatedPeddinghaus Paint Shop
Stores
Heated Paint Shop
CNC Machinery hall
Peddinghaus processing Peddinghaus angle masterplate machine Peddinghaus angle master machine Stores 6m x 2m flat bed plasma bed 6m x 2m flat bed plasma bed
Call Us at: (+353) 62 71102 email: info@dwyersteel.ie
Admin & Design Office
Call Us at: (+353) 62 7110 email: info@dwyersteel.
www.odwyersteel.ie
www.odwyerstee Call Us at: (+353) 62 71102
ADVERTORIAL
NEW FRAMING GUIDE FOR DESIGN TEAMS
METSEC HAS LAUNCHED A NEW DIGITAL SYSTEM PERFORMANCE GUIDE FOR ITS MARKET-LEADING PRE-PANELISED OFFSITE FRAMING SOLUTION – METFRAME. Available in two versions, one for Scotland which includes our improved SER submission support and the other for England and Wales, enabling specifiers to make informed decisions on system lining to meet client needs and achieve Building Regulation requirements. The new guide provides the project design team with information on performance, through wall build-ups and junction detailing for the most commonly selected Metframe solutions for external and internal walls. Metframe Sales Manager, Paul Mountford comments: “Whilst we have an extensive database of fire, thermal and acoustic performance based on independent laboratory tests, covering a multitude of combinations for Metframe stud used in conjunction with the most popular plasterboards, insulation, sheathing and finishes, we are looking to guide the readers directly to the options that best fit the bill. Following a consultation period with a number of leading Scottish engineering practices, we have improved and extended the level of support and information we provide to assist with the SER warrant application. We are pleased to include this with a number of recently tested acoustic wall build-ups specifically tailored to the Scottish market. “By presenting a selection of the most popular Metframe solutions, we hope
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to give designers and engineers an appreciation of what Metframe delivers and the time and cost efficiency benefits that can be realised for them and their clients. “Effectively, the new guide cuts to the chase, providing specifiers with concise information and clarifying the options available for the vast majority of situations. Of course, should a project have more involved requirements, our design team is able to draw on our extensive test data and broad experience to deliver solutions to suit.” Metframe uses 100mm or 120mm wide studs, similar to those used in Metsec’s loadbearing steel framing SFS system, which are bolted together to form a frame which is then used to create complete panels. Depending on stud width, this facilitates the construction of loadbearing structures for low to medium rise buildings of up to fifteen storeys in height. Panel assembly is undertaken offsite in a controlled factory environment, assuring precision and quality of the finished product, and exploiting the time and cost benefits of manufacturing processes. Completed Metframe panels are delivered to site according to the project’s construction programme and can be installed as soon as they arrive and are normally lifted into position
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straight from the back of the delivery vehicle. The speed and efficiency of the process allows the project to reap the benefits of just in time scheduling, rapid installation times, streamlined transport and installation logistics, and minimal requirement for on-site storage. Once installed, Metframe is ready for immediate use. With no requirement for curing and other time-consuming processes, follow-on trades can commence work in a short time, ensuring that the construction programme runs as smoothly as possible. Metframe solutions are designed and engineered to deliver optimum value and can accommodate a vast array of building types, from simple layouts to complex designs. They also allow a wide variety of external finishes to be applied, providing the designer with a high degree of freedom in the shape and appearance of the finished building. Metsec’s design solutions are BIM Level 2 compliant and come with the assurance of the MetWALL Perform, 30-year wall performance warranty and a £5 million professional indemnity insurance as standard – providing absolute peace of mind for the project design team. Paul Mountford concluded: “The new system performance guide underlines our commitment to the project design team; it offers a quick and easy digital reference for Metframe design solutions which adds to the impressive warranty and insurance package that comes as standard with our solutions. In addition to support for specific projects, we also provide CPD seminars to extend designers’ knowledge of our systems and their application.”
For more information visit: www.metsec.com
METFRAME
90 YEARS OF INNOVATION New Metframe System Guide coming soon
» MetWALL Perform, our 30 year wall performance warranty
» Independent and accredited Edge Protection system
» Free CPD seminars
» NHBC/SCI approval for up to 15 storeys
» £5m professional indemnity insurance as standard » Collateral design warranty
» Assembled in a controlled factory environment
» Rapid installation
» Site inspections
» BIM level 2 compliant
» Approved installer list
» Complex structures easily incorporated
» Multiple choice of plasterboard and sheathing board with test data
voestalpine Metsec plc www.metsec.com
PRODUCT INNOVATION
been delivered to market in record time, allowing us to meet the latest safety test standards.”
VANTAGE SF FS ®
TAKING A SAFETY-FIRST APPROACH
LEADING RAINSCREEN AND FACADE MANUFACTURER BTS FACADES & FABRICATIONS HAS BROUGHT A PIONEERING COMPLETE ‘THROUGH WALL’ SOLUTION TO MARKET. Taking a safety-first approach, the Vantage® Secret Fix-Full System (SF-FS) is tried and tested as a unitised solution and supplied as a complete kit of parts incorporating the external rainscreen facade, external boarding, light steel framing system, insulation, fire retardant membranes and internal boarding. Harnessing the Collective Power of Industry-Leading Experts Developed by BTS in collaboration with Etex Group partners EOS and Siniat, together with Siderise, DuPont, Knauf Insulation and SFS and Nvelope - the system is believed to be the first in the UK to have successfully completed two large scale testing regimes in accordance with the most recent BS8414-2:2020 standard. Tested in Belfast for fire performance by UKASaccredited laboratory Efectis UK and Ireland – Vantage® SF-FS successfully conforms to all stringent criteria for both internal and external spread of flame, as well as mechanical failure.
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This provides not only technical credibility but notably automatic approval for BR135 / AD.B.B4 of Building Regulations making compliance and approval easier to achieve. Importantly for designers and specifiers – certified assurance is now a pre-requisite for many tender opportunities, giving the new Vantage® Secret Fix-Full System a commercial advantage. A robust testing protocol was seen as an essential part of the product development strategy to not only gain a specification advantage in the open market but also to demonstrate technical prowess to a wider construction audience at a time when building safety performance is under rigorous interrogation. Mark Wiper, Technical Manager for BTS said: “Working collaboratively enables us to harness the collective intellect of industry-leading experts as well as deliver proven performance. Through the dedication and commitment of our supply chain partners the system has
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Assured Performance The Vantage® SF-FS product innovation adds real value by treating the external wall as a single item, delivering a complete ‘through-wall’ system as a fully tested and compliant package. This adds a new dimension to delivering performance assured, tried, tested and certified building envelopes. Taking the full external wall build from the construction site into controlled factory conditions delivers predictability of performance, programme and costs. The speed and accuracy achieved cannot be replicated using traditional construction methods. Contractors can shave months off build schedules which in turn reduces financing costs and shortens the period of construction liability. Enhancing Environmental Credentials Improving environmental impact, all elements of Vantage® SF-FS are cut to size, offcuts are recycled or reused – eradicating onsite waste. Eliminating cutting from the onsite environment also reduces accidents and improves Health & Safety. Delivered as a complete package on one vehicle vastly reduces transportation requirements and the associated costs, carbon emissions and disturbance to the local community. This safety-first approach offers the following benefits: • Tested system with either CWCT or BS8414-2:2020 • The stone wool core offers built in passive fire protection • A1 non-combustible and limited combustibility products A2 rated or better • Delivering excellent acoustic, airtightness and weathering performance The Vantage® SF-FS System is suitable for numerous applications across multi-storey residential projects, commercial builds, together with retail and leisure developments.
For more information visit: www.btsfabrications.co.uk
PRODUCT INNOVATION
UNI PANEL – DELIVERING HIGH LEVELS OF OFFSITE ADDED VALUE
Supporting a faster process for building RC frames, the panels also incorporate a head shutter which creates a perimeter for pouring the concrete floor above. Vastly improving productivity by removing the external wall from the onsite environment into a qualitycontrolled manufacturing facility - the ground-breaking UNI Panel systems can help deliver projects faster, more economically and with levels of quality unequalled by traditional construction methods. Research and Development UNI Panel can be supplied in configurations to meet 60 minutes and 120 minutes fire testing certification. Fire resistance testing has been carried out by BRE Global in accordance with EN 1364-1:2015.
WESTON GROUP HAS TAKEN A REVOLUTIONARY APPROACH TO CONSTRUCTION BY SETTING UP AN ADVANCED OFFSITE MANUFACTURING FACILITY OPERATING UNDER THE BANNER OF BRITISH OFFSITE. INITIALLY CREATED TO FULFIL THEIR OWN REQUIREMENTS FOR MORE INTEGRATED OFFSITE TECHNOLOGIES FOR THEIR PROPERTY DIVISION WESTON HOMES – BRITISH OFFSITE NOW OPERATE AS AN INDEPENDENT COMPANY OFFERING ADVANCED FACTORY MANUFACTURED PRODUCTS TO DEVELOPERS ACROSS THE UK.
From a purpose built 75,000sq.ft stateof-the-art manufacturing facility, British Offsite specialise in the design and production of superstructures as well as the interior fit out solutions. This offers total synergy across the supply chain making their construction systems some of the most competitive in the market. Developed to Address a Significant Need UNI Panel has been conceived to address a significant need to enable
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developers to progress reinforced concrete (RC) frame builds at a much faster pace to rapidly achieve a watertight envelope much earlier in the construction schedule. The complete infill walling system is constructed from light steel frame, insulated and protected with weather performance sheathing boards, with factory fitted windows, sealed within the panels. UNI Panel is then insulated externally and fitted with either brick tie channels or helping hand brackets depending on the facade details.
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The research and development for the UNI Panel systems was undertaken with Weston Homes Technical, British Offsite Technical and Globe Tooling, supported by a number of material suppliers. British Offsite has also worked with Randek AB to design a purposebuilt assembly line which will be the first of its kind to increase daily output by 600%. This line is due to be in operation in 2022. Champions of Precision Being part of a developer led group, British Offsite has an in-depth understanding and unique insight into the challenges and exacting requirements of the construction sector. Designing their own proof of concept manufacturing line, incorporating framing tables, automated screw bridges and three cranes – British Offsite can not only transfer products between the stations but also move the panels from horizontal to vertical as they transition through the line to aid the assembly. By assembling the frames horizontally in the factory on the framing tables, panels can be much larger than many other producers and so far, British Offsite has produced panels up to 3.4 m high and 9m long.
PRODUCT INNOVATION
The UNI Panel product also high levels of precision and offsite added value due to the range of processes carried out on the line. Panelised systems are available from other producers, but few add the windows offsite and even fewer also add the insulation and facade support systems in the factory.
unrivalled by traditional construction methods. Delivered as a complete assembled unitised system, provides economies of scale, predictability of costs and building programme, as there are no delays from extreme weather conditions. Using Design for Assembly and Manufacture (DfMA) protocols increases sustainability, as this approach value engineers the entire system ensuring the efficient use of materials and minimising waste. All factory offcuts are recycled or reused and specification of the UNI Panel system, eliminates onsite waste.
Operational Improvements UNI Panel brings operational improvements and enhances productivity. By removing the construction of the external wall from the onsite environment into a controlled manufacturing facility, levels of quality are attained that are
The factory fitting of all components achieves a highly airtight external walling system, enhancing energy efficiency, cutting heating requirements and reducing in-use carbon emissions for the lifetime of the building. Born to Build - Proudly British Part of the new high-tech manufacturing sector in the UK with a world class team, British Offsite are bringing the best of automotive manufacturing and the logistics industry to homebuilding.
For more information visit: www.britishoffsite.com
Your partner in delivering a
LIGHT GAUGE STEEL FRAME
to meet your project requirements
• MetStructures light gauge steel framing, NHBC and SCI approved to 15 storeys • 100mm external and internal LGSF walls • MetFloor composite metal decking and concrete • Fully finished balconies • Hot rolled steel podium structures • MetSafe accredited temporary edge protection system.
STUDENT ACCOMMODATION
HOTELS
• All elements designed, coordinated, supplied and installed on site. Should you have a project that you would like us to assist you with please contact: keith.wood@ keith.wood@metstructures.uk.com or andrew.warren@ andrew.warren@metstructures.uk.com who will assist with your project.
RESIDENTIAL
CARE
MetStructures LIGHT GAUGE STEEL FRAMING SPECIALISTS
Your exact project requirements Met t: 0121 380 1603 | e: info@metstructures.uk.com
www.metstructures.uk.com
ADVERTORIAL
RANDEK UK TEAMS UP WITH BRITISH OFFSITE TO PRODUCE THE FIRST ROBOTIC LIGHT GAUGE STEEL PANEL ASSEMBLY LINE IN THE UK Since the 1940’s Randek have been at the forefront of production and innovation of high performance machinery within the timber industry. With our fantastic production facility in Falkenberg and Robotic facility in Arvika, Sweden we are now able to adapt this technology to build offsite closed and open panel wall lines using Light Gauge Steel. British Offsite are set to become one of the biggest Light Gauge Steel housing manufacturers in the UK. They are the first customer in the UK to invest in one of our automation wall lines. With a factory in Braintree and a second factory opening soon we will be working in partnership with them to install and support this new system ensuring they are at the cutting edge of technology enabling them to increase production and produce more efficient housing to their customers using offsite methods, saving money and bridging the labour and skills shortages which have occurred post Brexit.
“Having invested £37M in our new factory in Braintree, we wanted a partner that could work with us to create a state-of-the-art Light Gauge Steel line to improve efficiency and increase production offsite, using Modern Methods of Construction. Randek are pioneers in this industry with over 60 years’ experience within the Global market and are constantly striving to improve and innovate their machinery from basic systems right up to fully Zero Labor robotic lines. We, at British Offsite have invested in the most advanced automated Light Gauge Steel assembly line. With a UK office now open providing sales, support and service we are confident in their ability to provide a full package and are looking forward to continuing our collaboration far into the future.” Shaun Weston, British Offsite
Image credit: British Offsite
“British Offsite’s new automated manufacturing facility is the first of its kind in Light Gauge Steel in the UK and a first for Randek UK. We are setting a new standard for building off site and helping push the industry forward in innovation. British Offsite will be able to provide quality, accuracy and deliverability to its projects and customers. We look forward to a long and rewarding partnership together.” Gordon Young, Randek UK
RANDEK UK sales@randek.com www.randek.com
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+44(0)1793378580
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OFFSITE EXPO
LIGHT STEEL FRAME SPECIALISTS OUT IN FORCE AT OFFSITE EXPO
Ellison from Fusion Building Systems. The CPD Accredited presentations on loadbearing steel systems for offsite housing, the change journey and attaining sustainability, efficiency, precision engineering with cost and programme certainty using light steel frame – were extremely well received. “We found the exhibition to be a little bit different this year,” said Clive Reeves, Customer Manager from Light Steel Framing Association member, Knauf. “Talking to visitors at the last event they were ‘thinking’ about the way they wanted to build – this year developers are much more confident in the offsite construction approach and wanted to know what solutions we could provide. Offsite Expo has been a very positive event for Knauf. We’ve generated quite a few leads and are looking forward to progressing them over the next few weeks and months.”
WITH RECORD ATTENDANCE AND THE EXHIBITION VENUE FILLED TO CAPACITY, ORGANISERS OF OFFSITE EXPO HAVE BEEN OVERWHELMED WITH POSITIVE FEEDBACK FROM DELEGATES, SPEAKERS AND EXHIBITORS. Sam Davies, Construction Director for British Offsite said: “The organisation of Offsite Expo 2021 was very professional and well executed. The event organisers were helpful and accommodating and the pre-planning of the event was exceptional in terms of communication and ensuring a successful delivery.” Across the two days of the event which was held at the Coventry Building Society Arena (Ricoh Arena) on 21 & 22 September 2021 – 3,054 delegates visited over 100 exhibition stands and feature builds which involved everything from a transporter hauling a module and a new innovative ‘room in the roof’ system to a double height light steel frame exhibition stand and even a twostorey apartment block. It was often standing room only in the three theatres where over 100 speakers delivered CPD Accredited Masterclass sessions. Mike Fairey,
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Director of Fusion Building Systems and Chairman of the Light Steel Frame Association (LSFA) presided over the light steel framing sessions on the first day of the event. To a packed audience Brian Alborough from Richard Hopkinson Architects, Joanne Booth from Lucideon and Andrew Waddell from Hadley Group shared knowledge and insight on offsite in an evolving world, the benefits of full-scale testing regimes and pre-panelised systems. Again, on day two there was tremendous interest in the light steel framing Masterclass sessions when Andrew Way, Associate Director of the Steel Construction Institute (SCI) chaired proceedings. Andrew was joined on the stage by Peter Burchill from EOS Framing who are part of Etex New Ways, Gus Houliston recently appointed Managing Director of Intelligent Steel Solutions and David
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Many exhibitors also reported that the Offsite Connect forum was a major highlight for them with over 330 productive business meetings taking place. Offsite Connect is a highly effective way for buyers and specifiers to meet with new and existing offsite industry suppliers exhibiting at Offsite Expo. Over 80 construction professionals with major buying remits participated from such high-profile companies as Barratt Developments, Persimmon, L&Q, as well as main contractors Willmott Dixon, Bam, Kier and Morgan Sindall. Julie Williams, Business Development Director for Offsite Expo said: “Offsite Connect is such a draw for exhibitors, and buyers equally find the business forum a major benefit as they can meet with so many offsite suppliers all in one place. This is just one of the reasons why 70% of this year’s exhibitors have already signed up to take part again in 2022 which is testament to a successful event.”
To secure you place at Offsite Expo 2022, go to ‘book a stand’ on the event website: www.offsite-expo.co.uk
OFFSITE AWARDS
OFFSITE AWARDS Taking centre stage at Offsite Expo on the evening of 21 September 2021, the Offsite Awards saw a major coming together of the industry when over 400 guests gathered to celebrate ground-breaking achievements and the pioneers who are developing radical new offsite technologies and landmark projects using factory-based methods. Attracting more than 200 entries, the Offsite Awards showcased many outstanding light steel frame projects and product innovations. Best Use of Steel Technology Always a highly competitive category, the five finalists demonstrated the versatility of steel framing solutions with a diverse variety of applications ranging from a modular affordable homes ‘airspace’ development built above a carpark, to creating student accommodation on top of a disused retail building and a mixed-use scheme designed to reference the shipbuilding industry with an unusual shape making it totally unique but extremely challenging to construct. To find out more about the projects that reached the finals and the Best Use of Steel Technology winner turn to pages 28 and 29.
Best use of Hybrid Technology Innovaré and Sika - Turves Green Girls' School
International Offsite Project of the Year
Best use of MEP & Pod Technology SES Engineering Services Lostock Sustainable Energy Plant
Offsite Pioneer of the Year Akerlof
Best use of Steel Technology MAS Architecture - 504 Bristol Road - Mixed Use Retail & Student Accommodation
Forta PRO - Kvarteret Jylland Student Accommodation
Private Housing Project of the Year Positive Homes and Dice Consulting Engineers - Eco-MMC by an SME: Small site - nationally significant Product Innovation Award
Best use of Timber Technology Wiehag GmbH- University of Warwick Interdisciplinary Bio Research Building
Integrated Health Projects in collaboration with Westgate Nightingale NW Manchester
Best use of Volumetric Technology Bond Bryan Architects - Springhead Primary School
Project or Construction Manager of the Year Rob Stanton, Kier - HMP Five Wells
BIM/Digital Construction Award Kane Group - Claridge’s Hotel
Retail/Leisure Project of the Year Hewitt Studios - Morgan Experience Centre
Building Performance Award Volumetric Modular - MODULHAUS™ Client of the Year Middlesbrough Council - BoHo 8 Commercial Project of the Year Reds10 - Parkside: Imperial War Museums’ Staff Offices Contractor of the Year Integra Buildings - Severn Trent Academy
- Bed Bay Partition System
Social Housing Project of the Year Fuse Architects - The Underwood Winner of Winners Volumetric Modular - MODULHAUS™
HIGHLY COMMENDED Best use of Steel Technology EOS - Renaissance Works
Education Project of the Year Reds10 - Addington SEN School
Best use of MEP & Pod Technology NG Bailey Group - UK Battery Industrialisation Centre
Engineer of the Year Engenuiti & BDP - The University of Central Lancashire Student Centre
Product Innovation Award Ultrapanel Building Technologies - Ultrapanel ‘Room in the Roof’
WINNERS ANNOUNCED Renowned for showcasing a rich vein of architectural achievement and engineering prowess, this year was no exception and one of the big winners on the night were:
Healthcare Project of the Year MTX Contracts - Norfolk and Norwich University Hospital – 3Storey Ward Development
Architect of the Year shedkm - House by Urban Splash Offsite Housing Range
Infrastructure Project of the Year Eric Wright Civil Engineering, Cumbria CC, GHD, Knight Architects, WEC, Mott MacDonald - Replacement Pooley Bridge
Best use of Concrete Technology PCE - Warwick Interdisciplinary Biomedical Research Building
Installer of the Year Wiehag GmbH - University of Warwick Interdisciplinary Bio Research Building
2022 22.09.22 COVENTRY BUILDING SOCIETY ARENA
The deadline for submissions for the next Offsite Construction Awards is 27 May 2022 with the winners being announced on 20 September 2022 at Offsite Expo.
Find out more by visiting: www.offsiteawards.co.uk
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OFFSITE AWARDS
BEST USE OF STEEL TECHNOLOGY – WINNER: MAS ARCHITECTURE
504 BRISTOL ROAD LOCATED IN SELLY OAK, BIRMINGHAM IS A NEW BUILD MIXED-USE SCHEME INVOLVING COMMERCIAL UNITS ON THE GROUND FLOOR AND PRESTIGIOUS STUDENT ACCOMMODATION SET ACROSS FOUR FLOORS ABOVE, TOPPED BY A LARGELY GLAZED AND SETBACK FIFTH FLOOR. Only a stone's throw from the University of Birmingham, the student accommodation comprises 70 selfcontained luxury studios with various internal and external communal spaces including study pods and a large courtyard. The challenge MAS Architecture faced was to provide a building of architectural merit that was equal to that of the existing Victorian building which occupied the site. The building was designed with references to its historic setting and the shipbuilding industry with the shape making it unique and innovative but equally challenging to construct. Considering the highly restricted access, lack of site storage space and time constraints, the design team concluded that the best construction solution would be hot rolled steel frame on the ground floor supporting
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a Comflor Transfer Deck to take four floors of cold rolled structural loadbearing steel above. A lightweight steel solution by Hadley Steel Framing was a perfect fit for this project. As a manufacturer they wanted to demonstrate that the conical form could be built utilising their light steel frame system and offsite construction techniques. As steel is such a versatile construction material, MAS Architecture were able to produce the innovative design as well as creating a structure that is both durable and safe. Calculations were made ensuring all structural components for the whole building frame (composite floor slabs and structural steels) were designed efficiently working within the project’s financial constraints. A highly costeffective digital approach produced steel framing systems that could be ‘virtually tested’. Due to Hadley Steel
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Frames’ advanced cold roll forming manufacturing methods, the steel frames could also be rapidly and cost-effectively produced, reducing design and manufacturing time whilst simultaneously ensuring outstanding quality and accuracy. Using a lightweight steel frame structure meant the project was delivered on time and on budget whilst maintaining the highest quality standards. Costs were easier to predict, as design specifications were met thereby reducing the cost of snagging and remedial works. Offsite prefabrication meant the frames were delivered when necessary. This quick turnaround meant that project timelines were decreased and ultimately costs such as plant hire and management costs reduced. Also using steel frame internal partitions makes it easier to convert the functionality of the building. Making the project a more ‘long-term’ and versatile scheme. The client and contractor were provided with a watertight building within three weeks, which allowed them to commence internal building work and the installation of the cladding system simultaneously. Light steel frame structures can be significantly lighter than concrete equivalents and require less extensive foundations, reducing the environmental impact of the build. Disruption to local residents and businesses were minimised as onsite construction time was reduced, transport to site and dust produced was much lower when compared to traditional building methods.
PROJECT TEAM Client: Avaro Midlands Limited Architects: MAS Architecture Building Contractors: Hive Developments Limited Structural Engineers: Howard Ward Associates Consulting Engineers: PRP Ltd M&E Engineers: SVM Building Services Chartered Surveyors: Edward Cooper Young Building Compliance: Salus
OFFSITE AWARDS
BEST USE OF STEEL TECHNOLOGY – HIGHLY COMMENDED: EOS
The former Co-operative building in Huddersfield town centre stood derelict for almost two decades. It has now been refurbished, expanded and reborn as Renaissance Works. With a mix of one and two-bedroom studios, with communal kitchens and lounge areas, along with onebedroom self-contained apartments – the project delivers a total of 138 student bedrooms through 75 apartments.
The innovative transformation uses EOS Framing’s loadbearing Thrubuild® system range to best effect to maximise space via a three-storey extension on top of the existing building. EOS designed, engineered and offsite manufactured a non-combustible Thrubuild® loadbearing solution for the three-storey roof extension together with a hot rolled steel staircase for the top three floors. In collaboration with Etex group partners, EOS developed the loadbearing Thrubuild® systems range with Siniat, Promat and FSi. These fast-track systems make use of the latest products, technical know-how and manufacturing excellence of the combined team. Thrubuild® delivered ‘all in one’ certified solutions providing crucial safety, time and cost benefits for the Renaissance Works project.
With 60, 90 and 120-minute fire resistance options, Thrubuild® has been used for multiple loadbearing applications within the project to form external and internal walls together with internal and separating floors. To offer total peace of mind for specifiers and the client, after having completed rigorous fire, acoustic, weathering, airtightness and mechanical testing, all Thrubuild® systems are supported by a 30-year warranty.
PROJECT TEAM Client: SKA Developments Main Contractor: Spring & Company Local Contractor: Big Red Construction Light Steel Frame Design, Engineering and Manufacture: EOS Framing
BEST USE OF STEEL TECHNOLOGY – FINALIST: INTELLIGENT STEEL SOLUTIONS
Situated in a prime location in one of London’s most recent creative neighbourhoods, Brent House at Wembley Place has become a recognisable asset to the community, providing much needed affordable housing, opening up access to surrounding streets and connecting communities.
appointed to deliver a full structural light steel frame solution for the £76million project. The 26,546m2 impressive mixed-used scheme includes two linear buildings of five principle blocks ranging from seven to 10 storeys high delivering 248 apartments and retail space together with a new landscaped public plaza . Despite the usual challenges associated with large projects, Intelligent Steel’s holistic and collaborative approach was invaluable in mitigating any emerging problems. 3D modelling and BIM enabled early clash detection and ensured a right-first-time installation.
Brent House was constructed in partnership with Henley Homes and Notting Hill Genesis Housing Association. Intelligent Steel were
The light steel frame solution offers excellent durability and also has numerous advantages in terms of energy and carbon reductions over
traditionally built schemes. The lightweight construction decreases concrete foundation requirements to reduce the overall carbon footprint of the building. Utilising steel cassette floors further assisted with the weight of the structure which allowed for significant savings in the ground. The Brent House building is estimated to be 70% lighter than an equivalent reinforced concrete frame scheme.
PROJECT TEAM Client: Notting Hill Genesis Housing Association Developer: Henley Construct Engineer: Fairhurst Light Steel Frame Design and Manufacture: Intelligent Steel Solutions
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OFFSITE AWARDS
BEST USE OF STEEL TECHNOLOGY – FINALIST: SIKLA UK | EIRE | ANZ SOLUTIONS
Sikla’s modular steel frames and height adjustable primary pipe supports are widely used in Energyfrom-Waste (EfW) plants for both water steam cycle and general piping elements. Collaborating with Hitachi-Zosen Inova, this was again within their scope of works for the Rookery South Energy Recovery Facility.
For the Rookery project Sikla were asked to support with the design and supply of solutions for 12 frames for pump skids (feed water, condensates, demi water) and heat exchanger skids together with piping and primary supports for water steam cycle, balance of plant and the turbine area.
were planned from an early stage of the project. Firstly, from a design perspective Sikla’s engineering team were dedicated to the task and equipped with software to collaborate and engage with their client to meet their specific requirements. Sikla also has a software solution to streamline the design process and take into consideration BIM (Building Information Modelling), assisting project planning, execution and handover. Also, when compared to conventional welded piping supports and skid frames, there is a 50% material weight saving on average with Sikla’s modular steel frames and 60% time saving when compared to conventional welded piping supports.
Over 6,000 Sikla pipe supports were installed achieving numerous benefits as the modular steel solutions
BEST USE OF STEEL TECHNOLOGY – FINALIST: ZED PODS effective solution for creating habitable spaces in otherwise undevelopable sites.
ZED PODs are highly innovative modular providers with in-house architectural, design and project expertise to manage the entire build process. Having developed a modular construction system based on a steel primary structure they are now delivering 25 affordable Zero Carbon homes for the local council in Bromley.
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The site is situated on an existing car park where ZED PODs are creating steel podium structures to develop the airspace above to meet local housing demand, whilst retaining the car parking capacity beneath. The modules utilise the benefits of steel as a primary structural material as its lightweight properties help to reduce the material usage of supporting structures and concrete foundations enabling a cost-
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Steel ITFCs and PFCs are used to create rigid floor and ceiling decks with loads distributed down through the centre and corner posts which frees the structures of loadbearing walls increasing design flexibility. The higher strength to weight ratio of steel has also permitted adaptability in fixings and attachments allowing a bolt together modular system to be developed for rapid on-site assembly. This has been a key component in reducing build times to less than 50% of a conventional construction system. Using steel as a primary structure has been instrumental in ZED PODs achieving a fabric first approach to reduce operational carbon emissions.
ADVERTORIAL ADVERTORIAL
THE SKILLS DILEMMA THE SKILLS DILEMMA FOR A GROWING FOR A GROWING LIGHT STEEL SECTOR LIGHT STEEL SECTOR Whilst ARV Solutions has been Whilst ARV Solutions has been placing professionals across the placing professionals across the2007, light steel framing sector since lightwas steel framing sector 2007, this historically not asince significant this was historically not a significant area for the offsite construction area for the offsite construction recruitment specialists - until recruitment specialists - until recent years that is. Here Jim Roach recent years that is. and HereFounder Jim Roach Managing Director Managingrecruitment Director andstrategies Founder in a discusses discusses recruitment strategies in a rapidly growing industry. rapidly growing industry. We have actually placed double the We haveof actually placed the amount candidates indouble the light steel amountthis of year candidates in the light steel sector than any other before! sector thisvery yearencouraging than any other before! This is all – however, This is all very encouraging – however, in a rapidly developing market there are in a rapidlyfactors developing market there are important to consider. important factors to consider.
As an ethical recruitment business in As anmarket ethical for recruitment business this the long term, we in shy this market the long term, we away fromfor actively poaching of shy staff away actively poaching of another. staff fromfrom one specific business to from one specific business to another. There could be a short-term gain but it There a short-term it bringscould long be term issues bothgain for but us, and brings term bothThe forproblem us, and for thelong sector asissues a whole. for sector as net a whole. Theanyone. problem is –the there is no gain for is – there is no net gain for anyone.
Recruitment has always been Recruitment in has always been competitive offsite construction competitive in offsite construction related markets, and from time to time related markets, and from time to time we have seen active poaching running we have seen active poaching running rife. We have seen employers targeting rife. We have seen employers targeting their competitors to bring in relevant their competitors to bring in relevant skills and the inevitable retaliation. skills and the inevitable retaliation.
For the future success of a rapidly For the future success of a to rapidly growing sector, we need move away growing sector, we need to move away from short-term answers. The solution from short-term answers. The solution for the long-term is to attract more for the long-term is to attract more people into the sector. They then need people into the sector. They then need to be well trained and developed to to be well trained and developed to progress within the industry. progress within the industry.
We are seeing employers becoming We are seeing employers becoming more open to bringing in skills and more open to however bringing in skillsisand cross-train, there still a cross-train, there is still a reluctancehowever at least initially, to consider reluctance at least initially, to consider people from other industries. people from other industries. New sectors need new thinking. If you New sectors need newdid, thinking. If you do what you always you will get dowhat whatyou youalways alwaysgot. did,We youlook will get forward what you always got. We look forward to seeing the sector continue its growth totrajectory, seeing thethrough sector continue bringingits in growth new trajectory, bringing newtake it skills andthrough new thinking to in really skills and new to really take it forward to itsthinking best potential. forward to its best potential.
For more information visit: For more information visit: www.arvsolutions.co.uk www.arvsolutions.co.uk
The Market Leading Recruitment Consultancy for Offsite Construction.
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CERTIFIED PERFORMANCE
PIONEERING A NEW SFS APPROACH
“More effective testing regimes with clearer labelling and product traceability, in order to drive continuous improvement, higher performance and encourage innovative product and system design under better quality control.” We believe material providers should have full-scale testing regimes that study the performance of products working together to see how they interact in ‘real’ circumstances, like under fire conditions or when exposed to wind and rain. Our research and perspective interviews with sector experts has equipped us with a deep understanding of the challenges faced by specifiers. Lack of performance testing is a major concern.
SPECIALISING IN ADVANCED LIGHT STEEL TECHNOLOGIES, EOS FRAMING IS TAKING THE CONSTRUCTION INDUSTRY FORWARD BY PIONEERING A NEW CERTIFIED SYSTEMS APPROACH. MANAGING DIRECTOR, STEVE THOMPSON DISCUSSES HOW IN CLOSE COLLABORATION WITH ETEX GROUP PARTNERS – EOS HAS TAKEN FACTORY PREFABRICATION AND PREASSEMBLY TO ANOTHER LEVEL.
Delivering Predictable Performance in One Unitised Solution Following the outstanding success of our Thruwall® system which is supplied as an offsite manufactured kit of parts, we have developed and rigorously tested our custom-manufactured Pre-Assembled Frames (PAF) which are an evolution of Thruwall® delivered to site as a unitised non-loadbearing infill system. Delivering crucial cost and time benefits making programme savings of up to 30%, our PAF system offers
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60-minute fire resistance and provides a 30-year product and performance Etex warranty. This revolutionary next generation system increases the speed of build without compromising on safety, quality, or performance – to deliver a faster return on investment. Mitigating Risk The performance of building materials is under an unprecedented spotlight. Architects, designers, specifiers and ultimately, clients – are feeling exposed. In her report ‘Building a Safer Future’, Dame Judith Hackitt recommends:
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Pre-Assembled Frames Developed to eliminate uncertainty surrounding the design and specification of the external envelopes, our Pre-Assembled Frames have been created to meet industry demands. Precut, prefabricated and pre-assembled offsite in controlled factory conditions, these non-loadbearing infill systems are delivered to site as an assembled panelised unit encapsulating EOS light steel framing and external Siniat Weather Defence boarding, ready for glass mineral wool insulation and Siniat internal wall linings to be fitted onsite. Developed in collaboration with our Etex Group partners, Siniat, a leading expert in plasterboard and drylining, together with fire protection specialists Promat and FSi – our manufacturer backed system approach helps to design out the complexities surrounding individual components. With a comprehensive list of performance elements – energy efficiency, acoustics, fire performance, weather resistance and durability – backed by rigorous testing, our Pre-Assembled Frames get the system performance right through the combination of: Light Steel Frame Our fully engineered light steel frame systems are custom designed according to the specific project requirements and preassembled under ISO 9001:2015 quality management systems and ISO14001:2015 environmental
CERTIFIED PERFORMANCE
management standards. The steel framing system selected will depend on the height of the infill wall, the weight of the cladding and the wind load. External Sheathing With two BBA Certificates, Siniat Weather Defence™ is a revolutionary external sheathing board faced with water repellent material for superior weather protection. Strong, highly moisture resistant and Euroclass A1 fully non-combustible, Weather Defence™ is suitable for buildings over 18 metres and can be left exposed on site for up to 12 months. Internal Wall Linings – Site Applied Depending on the performance criteria of a project an appropriate Siniat internal wall lining can be selected to provide enhanced levels of sound insulation, fire, moisture, impact or vapour resistance.
All our components and products are rigorously tested together as a complete system to ensure compatibility, enabling us to award the technical performance of our Pre-Assembled Frames range with a 30-year Etex warranty which is available following a specification and validation process. We are committed to technical competence and as part of Etex, we have some of the best building performance experts in the UK on our team. They work closely with certification bodies to jointly develop and design advanced technical solutions.
30 YEAR
*
WARRANTY
Watch the EOS PAF video: https://bit.ly/3ntj7Dk Download the PAF brochure: https://bit.ly/2ZlPNXa
For more information visit: www.eosframing.co.uk
PRE-ASSEMBLED FRAMES FACT FILE Pre-Assembled Frames deliver vast cost and programme savings and ultimately achieve a faster return on investment. • Product and performance Etex warranty
Insulation – Site Applied Etex specify the use of glass mineral wool at a minimum thickness of 100mm, λ0.035 or better within the studs of the panel and rock mineral wool within the head deflection detail of the panel.
• Rigorously tested for certified performance • Fire tested to 60 minutes (integrity and insulation) to EN1364-1 in both directions • Fire Tested EOS Perimeter Fire Gasket developed for the PAF system • Application as infill panelised systems for steel or concrete mainframes • Suitable for buildings with a height of more than 18 metres • Delivers crucial time benefits making programme savings of up to 30%
30-Year Warranty Our range of technical support is there for specifiers throughout the lifecycle of the project. Our testing regimes are designed to ensure that our PreAssembled Frames give specifiers complete peace of mind knowing that our systems have been subjected to relevant testing for fire, acoustic, weathering, airtightness and mechanical performance.
• Offers the best strength-to-weight ratio to improve efficiencies • Installation from inside the structure reduces working externally at height • Reduces mast climber and scaffolding requirements offering vast cost savings • Just in time deliveries save space on site storage • Site waste is virtually eliminated saving disposal costs • Preassembly and prefabrication take months off construction schedules • Delivers a faster return on investment
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ADVERTORIAL
SHIFTING TO LIGHT STEEL MANUFACTURING? HERE ARE 7 TIPS TO HELP MAKE THE TRANSITION
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LIKE ALL BIG INVESTMENTS, BUYING THE MACHINES AND TECHNOLOGY FOR CONSTRUCTION MANUFACTURING WITH LIGHT STEEL TAKES CAREFUL PLANNING TO ENSURE A PROFITABLE OUTCOME. HERE IS A QUICKFIRE CHECKLIST OF SEVEN KEY CONSIDERATIONS:
1. Can you quickly optimise machine time? The scale of your operation will play a major part in your decision to manufacture in-house with your own machine. As a rule of thumb, a full pipeline of ongoing projects with multiple properties will produce a positive return on investment on machine costs within 12 to 18 months.
2. What applications do you build for and how will this change? Light gauge steel is ideal for frames, trusses, joists, flooring and interior infill framing. Do you need to produce loadbearing frames and trusses? The level of variability in the types of framing and profiles needed will impact the type of machine and the specifications of any adaptions required.
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3. Do you have experience in constructing with steel? Most building companies who transition from traditional construction find it relatively easy, but a steady transition is always recommended. Talk to others who have made the shift and learn from their experiences. 4. Do you use design-led construction and BIM software? Adopting a design-led construction practice using 3D modelling keeps re-work down, fast-tracks build times and improves profitability. There is a plethora of 3D construction modelling and Building Information Modelling (BIM) software available, but it takes experience to get the most out of it. For success, consider any investments needed in design expertise as well as the capital costs of machinery.
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5. How much manufacturing space do you have? It is easy to under-estimate the space requirements for a busy manufacturing and assembly plant. Allow for the machine footprint, feeder space for a decoiler, output space and assembly. You will also need storage space for completed framing components and frames ready for distribution. This should be conveniently located for fast and safe access to a loading bay, with easy access for transport used for distribution to site. 6. Framing software Check that the machine you select is enabled to work with your preferred design software if you have one. This will save time in training and getting your machine up and running quickly. 7. Ongoing running costs Check that there are no hidden royalties, toll fees or software license fees to pay to the manufacturer. Doing so can save you big time over the life of a machine. Getting to a Return on Investment Fast Howick have produced a detailed guide to help construction businesses negotiate many of the pitfalls of machine acquisition. Check out the free Machine Buyer Guide on the Howick website at www.howickltd.com
IMAGES 01-02. Light gauge steel is ideal for frames, trusses, joists, flooring and interior infill framing.
Introducing our dedicated range of connectors and fasteners for light gauge steel. Manufactured and performance tested for fast, cost efficient off-site construction. @strongtieUK
Connect with us: 01827 255600 | www.strongtie.co.uk |
SUPPORTING THE DEVELOPMENT OF LIGHT STEEL FRAME CONSTRUCTION DEDICATED LIGHT GAUGE DIVISION
Our dedicated supply only division are happy to help with customers design and installation queries.
SMD
FLOOR DECK SOLUTIONS
Our product range and crushed end finish is perfect for the light gauge solution.
Structural Floor and Roof Solutions
DEDICATED PRODUCTION LINE
Due to demand, our dedicated production line manages large volumes and quick delivery times.
www.smdltd.co.uk
CASE STUDY
SIGMAT DELIVERS NINE STOREY HOTEL IN DEVON
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OPENING IN FEBRUARY 2022, SIGMAT ARE AT THE FINISHING STAGES OF THE CONSTRUCTION OF A NEW NINE-STOREY MARRIOTT INTERNATIONAL HOTEL CLOSE TO THE CITY OF EXETER IN DEVON. THE NEW ‘COURTYARD BY MARRIOTT’ WILL BE THE LARGEST COMMERCIAL HOTEL IN THE REGION WITH 250 BEDROOMS, GROUND FLOOR LEISURE FACILITIES AND A SPECTACULAR ROOFTOP COCKTAIL BAR. Working with Exeter based KTA Architects, Sigmat have been involved in delivering an all-encompassing offsite MMC solution including four-levels of hot rolled steel transfer structure with Sigmat’s own infill steel framing systems (SFS), five-levels of Sigmat light steel framing (LSF) with 160mm SMD decking throughout the whole scheme, including provision of roofing, lift / stair cores and staircases. In keeping with the architects detailed design for the outer wall, Sigmat were required to precision design and manufacture every stud to the external walls which were pre-pierced to receive the fixing point for the horizontal rail
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on each floor, to support the feature vertical fins. This unique approach was employed to deliver on the architectural designs specifics to create an impressive wave effect across the building. Commenting on the ground-breaking design specifications, Sigmat’s Darren Hooley, said: “By installing the SFS at the same time as the pre-assembled panels on the upper levels, this allowed other trades to follow straight behind with their works, which in turn accelerated the overall programme of works significantly. As the build progressed it was extremely rewarding to see the hotel gain landmark status in the south
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west, the final highlight of which was the completion of the bespoke link bridge which we installed from the Exeter Chief’s main car park direct to the hotel reception. This has been a tremendous project to be involved with.” Alongside additional architectural features such as vertical aluminium brise soleil which helps to manage heat and light, the heart of the scheme also includes a bespoke, hot-rolled glazed link bridge which offers seamless access from the hotel reception to the nearby Sandy Park stadium, home to the Exeter Chiefs Rugby Club.
CASE STUDY
02 Sigmat’s Design Director Anthony Longbottom said the hybrid nature of the scheme had created unique challenges: “The scheme presented a number of key structural challenges; The vertical brise soleil fins were up to 17m long and fixed directly to the light steel frame external wall studs. Torsion of the light gauge sections was prevented using an innovative rail system which also allowed for onsite tolerance and adjustment when installing the fins. A hybrid design utilising slender hot rolled posts and braced light gauge steel panels at the upper floor allowed for a large open plan space with continuous glazing down the full elevation. “Another key architectural feature was the gull wing roof with 62m2 central opening over the roof top bar area. To create this, our engineers designed a series of plan trusses within the roof structure requiring complex wind modelling and stability analysis. The project was a really exciting one to be involved with and relied heavily on Sigmat’s wealth of hot rolled and cold rolled design expertise.”
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Lead architect on the project, Adam Willis, from KTA commented: “This has been a ground-breaking project for us. The hybrid approach of using hot-rolled to level three of the structure and light steel framing for all upper floors has offered us huge amounts of flexibility and really demonstrated the effectiveness of LSF as a leading value engineering solution.
for this type of scheme such as the speed of construction onsite and the flexibility to create a cost-effective, custom engineering solution that really delivers.”
For more information visit: www.sigmat.co.uk
IMAGES
“LSF is an amazing system for the right project and has huge benefits
01-04. Mariott International Hotel – Exeter
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ADVERTORIAL
OFFSITE EXPO SHOWS THAT MMC IS THE FUTURE OF UK CONSTRUCTION JULIAN VENUS, BUSINESS DEVELOPMENT DIRECTOR AT AQUARIAN CLADDING, REFLECTS ON THIS YEAR’S ENORMOUSLY SUCCESSFUL OFFSITE EXPO, AND WHAT HE LEARNED ABOUT THE STATE OF THE SECTOR IN 2021. For me, and everyone who attended from Aquarian Cladding, September’s Offsite Expo was a fantastic experience. It was not just an extremely valuable opportunity to meet thousands of people from right across our sector, but also to take the temperature of the industry, and feel part of a thriving, forward-looking community. Thanks to Offsite Connect, I was able to have some excellent conversations with a number of leading housebuilders, and learn about their aims, concerns and frustrations first-hand. Some topics came up again and again – but by far the most common was the huge difficulties companies are facing simply trying to build enough houses. I spoke to several businesses who desperately want to build more, but
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just do not know how they can do it using conventional methods. There is a growing sense that now’s the time for the sector to fully embrace MMC. That was borne out in the extremely enthusiastic response to the marketleading Aquarian Cladding products we brought with us to Coventry, and the diverse range of framing systems brick cladding can benefit, none more so than light steel frame. In a sector wracked with materials shortages, and that is struggling to get anywhere near the government’s 300,000 a year housebuilding target, solutions like Gebrik were very warmly received. An innovative insulated brick cladding system manufactured under factorycontrolled conditions, Gebrik can
LIGHTSTEELFRAMINGMAGAZINE.CO.UK
reduce deliveries by as much as 75% and cut storage by up to two-thirds compared to traditional brickwork, while coming in at about a quarter of the weight. It’s also four to five times quicker to install. Delegates were also very excited by MechSlip, our mechanically secured cladding made from natural clay bricks. Building a house with MechSlip can require half the amount of bricks needed to create a brick facade by using both sides of some soft mud bricks – hugely valuable at a time when many firms are facing 20 week waiting lists. MechSlip enables residential builders to build more houses using their current brick allocation. Meanwhile, NaturAL-X enables builders to not use their brick allocation at all by using a purpose made slip tile, as does
ADVERTORIAL
our Terracotta Rainscreen, so with such an extensive product portfolio you can see why we were busy!
Turves Green Girls’ School - but all nominations were exemplary in their own right.
Elsewhere, we were delighted to sponsor the Best Use of Hybrid Technology category at the Offsite Awards, held as part of the twoday Offsite Expo. I had the honour of personally announcing the very deserving winners - Innovare and Sika for their outstanding work on
All in all, the Offsite Expo was a brilliant experience for us at Aquarian Cladding. We look forward to progressing some of the very promising conversations we had with leading companies during the event, and we are already working on plans to be back again in 2022. Hope to see you there!
STRIKINGLY VERSATILE
Working with architects, contractors, developers and installation specialists, Aquarian’s cladding systems have been used on many award-winning buildings across a wide range of sectors.
For more information visit: www.aquariancladding.co.uk
With the Gebrik cladding system, you are assured of a simpler, faster brick façade that performs precisely as it should. Tried, tested and simple to install, our solutions provide you with the freedom to create strikingly versatile buildings.
To find out more, visit our website www.aquariancladding.co.uk 0044 (0)808 223 9080 info@aquariancladding.co.uk @aquarian_cladd
CASE STUDY
PREMIER INN’S £12M FLAGSHIP OXFORD HOTEL EMPLOYS LSF FOR COMPLEX DESIGN SOLUTION FRAME
JULY 2021 SAW THE OPENING OF PREMIER INN’S FLAGSHIP OXFORD WESTGATE. CONTRACTORS CARTER LAUREN CONSTRUCTION AND ATKIN TRADE SPECIALISTS NAVIGATED THROUGH THE COVID-19 PANDEMIC TO DELIVER THE LATEST ADDITION TO WHITBREAD PLC’S PROPERTY PORTFOLIO. SIMON PRYCE - DIRECTOR AT PROJECT ARCHITECTS, AND LSFA MEMBERS, ALLISON PIKE PARTNERSHIP – REFLECTS: The design, which was developed in collaboration between Allison Pike Partnership and MICA Architects, was carefully considered to reflect the sensitive historic location, sandwiched between listed buildings and a new public square. The new hotel makes a positive contribution to its city centre setting by preserving and enhancing views of adjacent listed buildings. The preservation of visual and physical routes around the site have shaped a building that features stepped roof levels and a mixture of angled and
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projecting windows – all readily achieved by the Metframe light steel frame structure manufactured by voestalpine Metsec. Light Steel Frame Solution Metframe was the obvious choice for us. As with most city centre sites, space is at a premium so maximising prefabrication of components and minimising construction waste is key. The hotel as a building type certainly lends itself to a Metframe system, with a repeated footprint of 3m x 6m
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bedrooms forming both the bedroom spaces and the structural frame. Although not required by Building Regulations, Premier Inn requires each room to be formed as a fire compartment, therefore each dividing wall combines the functions of fire and acoustic separation between bedrooms and fire protection to the structure in a highly efficient manner. The ability of the Metframe system to accommodate a concrete floor structure was also a major benefit, achieving the necessary acoustic separation between floors
CASE STUDY
without the need to install floating floor coverings, again reducing trades and the number of operations on site. The building design required a number of quirky details such as projecting windows and angled brickwork reveals, all of which were easily accommodated by Metframe designers with the introduction of some hot rolled elements into the facade. Fully modelled 3D Metframe details are an incredibly useful tool to both the architects and construction site team – giving us design certainty and simplifying site setting-out for the follow-on trades. Reducing the Fire Load As a practice, we have been engaged in offsite construction methods for a number of years. We are increasingly turning to light steel framing on urban and more complex sites with the added benefits of reduced fire load and reduced fire risk to adjacent buildings compared to more traditional timber frame methods. The benefit of any type of prefabricated framing system is the ability to get the structure up, enclosed and water tight as soon as possible, taking the structure off the critical path as early in the programme as possible so the team can focus on internal finishes and external cladding. Metframe gives us the ability to create more complex facades and shapes while taking full advantage of the benefits presented by offsite methods of construction.
Oxford Westgate – The Back Story Whitbread, which owns the Premier Inn hotel chain, started working on plans for the hotel in 2013 following the acquisition of a 1980s office building which originally occupied the site. The redevelopment provided the opportunity to improve and enhance Paradise Square, a public space adjacent to the hotel, and 27 new jobs have been created at the hotel on opening. Richard Aldread, Head of Construction in the UK regions and Ireland for Whitbread, said: “We spotted the opportunity to bring Premier Inn’s affordable bedrooms into the heart of Oxford city centre around the time the plans to redevelop the Westgate Shopping Centre were being
discussed. With the help of a talented team of designers and development professionals, and the support of City Council officers, we have built a superb new hotel in a challenging setting. It’s a proud moment to see the hotel open and I have no doubt that it will be extremely popular with our business and leisure guests and play a positive role in supporting the city’s economy.” Sustainability Strategy Whitbread’s sustainability strategy, ‘Force for Good’, is focused on helping the company’s customers, team members and suppliers to live and work well. The strategy is grouped into three key pillars of Opportunity, Community and Responsibility with long-term strategic commitments set for each.
For more information visit: www.allisonpike.com
CONSTRUCTION PARTNERS Architect: Allison Pike Partnership Ltd Design: Allison Pike Partnership Ltd with MICA Architects Ltd Client: Whitbread PLC Engineer: Simpson TWS Main Contractor: Carter Lauren Construction Ltd Installer / Client: Atkin Trade Specialists Ltd Materials / Type of System used: Metframe by voestalpine Metsec
For more information on the Force for Good strategy and how Whitbread measure and report against objectives go to: www.whitbread.co.uk/sustainability/ To find out more about Oxford Westgate go to Whitbread’s YouTube channel: https://www.youtube.com/watch?v=avfFD3AwaAI.
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BUILDING PERFORMANCE
THE POWER OF DYNAMIC SIMULATION MODELLING
this geometry is optimised by implementing passive strategies for high building performance. A range of highly developed software tools are then used to calculate and assess a building’s environmental performance. A wide range of factors are taken into consideration including (but not limited to) a building’s location, shape and orientation, fabric insulation, glazing, heating and cooling systems and controls, thermal mass, airtightness, ventilation strategies and renewable energy technologies. The skill is in the expertise with which the 3D model is developed and in how the various data fields are analysed. Innovative and imaginative design of complex details allows for trade-offs between specific requirements to be experimented with to ensure that the most cost-effective overall design solution is delivered to the client.
LIGHT STEEL FRAME ASSOCIATION MEMBER EVOLUSION INNOVATION PROVIDES EXPERT DYNAMIC SIMULATION MODELLING SERVICES TO THE SECTOR, DELIVERED BY THEIR HIGHLY QUALIFIED AND EXPERIENCED BUILDING PHYSICS TEAM.
What is Dynamic Simulation Modelling? Dynamic Simulation Modelling (DSM) is an exceptionally accurate and powerful computer-based software simulation engine for assessing the environmental performance of a building. Using DSM, building performance can be simulated for every hour in a year. Therefore, results for 8,760 hours can be viewed and analysed for critical design decisions. It allows for a very detailed thermal model of a proposed building to be created for a more accurate assessment of prospective heating, cooling and ventilation issues that may arise.
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By modelling a building using DSM engines, a deeper and more effective analysis can be performed, enabling users to better respond to and comply with planning and regulatory demands, while simultaneously addressing economic drivers. The modelling helps to optimise the performance at early stages of the design, which in turn leads to achieving environmentally friendly buildings and cost-effective solutions. The Process Architects’ basic building geometry is used to carry out a detailed analysis, and through iterations of simulations
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Applications DSM has up until recently been more commonly used for buildings other than housing such as hotels, office buildings and mixed-use developments for example, but with the increasing complexity of building regulations and the need to optimise costs by managing materials and methodologies, it is becoming the practice to use DSM for the analysis of residential developments. By more appropriately taking account of factors such as solar gain, and accurately analysing occupancy and behavioural factors, DSM provides a more detailed, accurate, comprehensive and integrated analysis than is possible with calculation tools such as DEAP, SAP and SBEM. DSM enables Evolusion to provide their clients with demonstrations of necessary regulatory compliance. The power of the software tools also allows for strategic and beneficial bespoke designs to be developed, including for example, overheating risk assessments and CIBSE Heating and Cooling Load Calculations.
For more information visit: www.evolusioninnovation.com
ADVERTORIAL
LIDL LAUNCHES NEW STORE AND APARTMENT COMPLEX
DESIGNERS FROM GERMAN INTERNATIONAL DISCOUNT RETAILER LIDL HAVE WORKED WITH EPSOM COUNCIL TO DEVELOP A SCHEME SUITABLE FOR THE LOCAL AREA. DELIVERING THE BEST UTILISATION OF THE SITE – THE SCHEME WILL CREATE A NEW STORE WITH WAREHOUSE, CHILLER AND BAKERY ALONG WITH EIGHT ONE, EIGHTEEN TWO AND FOUR THREEBEDROOM APARTMENTS. Adston Construction were nominated the overall contractor for the build, and they awarded the steel framing package to Blueberry Projects. Ayrshire Metals’ sales and design teams collaborated with Blueberry to deliver a fast-track build method to meet the timescale demands of the project. With over 100 years of experience, the Ayrshire Group can be relied upon to deliver the design and manufacture of light gauge steel sections for any scheme. Ayrshire carried out initial design, feasibility studies and structural calculations, utilising their in-house engineers and CAD team. The coldrolled steel was then produced at their advanced manufacturing facility in Daventry, Northamptonshire. Ayrshire’s design team were involved heavily in the early stage of the tendering process. This provided a cost-efficient solution that met the architect’s requirements for the specified wall types.
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By involving Ayrshire Metals early in the process, it allowed the various design teams to collaborate in overcoming any issues, enabling a fast and efficient install of the light steel framing system (SFS). Ayrshire Metals also deliver CPD’s to architects and engineering companies, along with toolbox talks to main contractors and installers, thereby educating best methods and practices within the industry. This allows individuals not only to understand the benefits of using light steel framing but to explain how to build fast and light, while saving time and money on material and design costs. This helps to overcome any common misconceptions within the industry regarding the limitations of using cold rolled steel sections. It shows how versatile the systems are and how sections can be used for a number of projects across a wide range of sectors.
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2021 has created a changing and challenging landscape for many aspects of the construction industry. Supply shortages and cost increases on most materials resulted in longer lead times and price increases. This coupled with the need to make certain of compliance with the necessary regulations can prove difficult when some products have not been available. Ayrshire Metals have overcome these challenges by working extremely closely with supply chain partners to maintain a good level of steel availability. Ayrshire’s ability to provide fire test details for up to two hours on throughwall build-ups, reduces lead times and accelerates design turnarounds, improving the ability for projects to hit the required target dates.
For more details email: sales@ayrshire.co.uk, call: 01327 300 990 or visit: www.ayrshire.co.uk
Ayrshire Metals Limited
Leading manufacturer of cold rolled steel
STEEL FRAMING SYSTEMS (SFS)
Contact Us: Ayrshire Metals Limited Tel: +44 (0) 1327 300990 Email: sales@ayrshire.co.uk www.ayrshire.co.uk
Our SFS systems offer numerous benefits from speed of build to the lightweight nature when compared with masonry and timber building structures. The load and span carrying capabilities of our light steel frames make this form of construction ideal for a wide range of building types, from schools to hospitals and residential to student accommodation.
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FIRE SAFETY
ACHIEVING FIRE SAFETY COMPLIANCE WITH NON-COMBUSTIBLE CAVITY TRAYS CAVITY TRAYS ARE AN ESSENTIAL PART OF MASONRY BUILDINGS, DIRECTING MOISTURE AWAY FROM THE INNER LEAF, REDUCING THE RISK OF DAMP. HOWEVER, AS MASONRY CONSTRUCTION MOVES AWAY FROM TRADITIONAL BLOCKWORK MAIN STRUCTURES THERE ARE ADDITIONAL FACTORS TO CONSIDER WHEN CHOOSING THE RIGHT SOLUTION— ESPECIALLY WITH REGARDS TO FIRE PERFORMANCE. Fire performance of cavity trays in ‘relevant buildings’ Applicable since the end of 2018, changes to Approved Document B (Fire safety), Regulation 7 state that for high-rise residential and other relevant buildings over 18 metres, cavity trays (alongside other key facade elements) must achieve an A1 or A2s1,d0 Euroclass rating, unless they are between two leaves of masonry. This means that any cavity trays being
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installed between a SFS inner leaf and masonry outer leaf must be classified as non-combustible to be compliant. Initially, this was achieved by using a metal cavity tray which is packed out with non-combustible insulation on site — which is time consuming, difficult to ensure high quality and lacking in flexibility. However, after a few years of prototyping and engagement with contractors and industry bodies such
LIGHTSTEELFRAMINGMAGAZINE.CO.UK
as the BBA and NHBC, solutions are now coming to market which combine flexible aluminium cavity trays with integral, pre-compressed non-combustible insulation to offer a single-component solution ideal for SFS constructions. Simple solution, simple installation The factory-engineered nature of noncombustible cavity trays bring a number of key benefits. In a practical sense, the single component allows for a quick, precise installation, requiring just a cutting knife and sealing tape with no need to add additional insulation. Tests conducted in classroom conditions found that this was around eight times faster to fit than traditional approaches, allowing an installation rate of up to 100 linear metres an hour . As a single component, they not only provide reliable performance and quality, but also can be holistically tested to ensure accurate fire performance classification, offering peace of mind that the product as installed is fully compliant. Meanwhile the flexibility of the aluminium tray, combined with the compression of the insulation, allows the product to flex with the natural movement of the building, ensuring integrity and continuity of weatherproofing. To learn more about non-combustible cavity trays go to: www.siderise.com/products/ construction/nc-ct-non-combustiblecavity-tray
For more information visit: www.siderise.com
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STEEL CONSTRUCTION INSTITUTE
TECHNICAL DEVELOPMENTS AFFECTING LIGHT STEEL FRAMING
THE SCI (STEEL CONSTRUCTION INSTITUTE) PROVIDES ESSENTIAL TECHNICAL EXPERTISE AND RELATED SERVICES TO THE STEEL CONSTRUCTION INDUSTRY. ANDREW WAY, ASSOCIATE DIRECTOR AT SCI PROVIDES AN UPDATE ON TWO RECENT TECHNICAL DEVELOPMENTS AFFECTING THE LIGHT STEEL FRAMING SECTOR. SCI Stage 1 Certificates for LABC Warranty and Premier Guarantee Both LABC Warranty and Premier Guarantee have recently released new versions of their technical manuals. These manuals identifying the Functional Requirements that are applicable to the design and construction of buildings to be covered by their Warranties. The latest manuals incorporate numerous changes from the previous versions however, of vital significance to the light steel framing sector is the implementation of SCI Stage 1 certificates specifically produced for the requirements of LABC Warranty and Premier Guarantee and their accompanying technical manuals. SCI has been reviewing systems and providing Stage 1 certificates for light steel framing systems that meet the
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necessary requirements for NHBC for 20+ years. There are currently over 30 companies which hold an SCI/ NHBC Stage 1 certificate, the full list of companies is available on the SCI Certification and Assessment website. These and other companies now have the opportunity to obtain equivalent certificates specifically for LABC Warranty and Premier Guarantee. Comparison of the relevant parts of the LABC Warranty and Premier Guarantee technical manuals with the NHBC Standards shows that there are some significant differences between the technical requirements of these companies for light steel framing. Part of the SCI service will be to ensure that standard details, design procedures and construction practice satisfy the pertinent requirements.
LIGHTSTEELFRAMINGMAGAZINE.CO.UK
Companies wanting to obtain Stage 1 certificates for LABC Warranty and Premier Guarantee (or NHBC) should contact SCI (assessment@ steel-sci.com). After companies have successfully completed the process SCI will issue their certificates, provide Stage 1 logos specific for the warranty provider, notify the relevant the warranty provider(s) and add the light steel framing system to the SCI Certification and Assessment website. SCI confirms corrosion protection performance of Magnelis® Metallic coatings on thin gauge steel are commonly used to provide corrosion protection in a range of applications such as light steel framing, cladding sheets and purlins and rails in industrial buildings. The steel is manufactured to EN 10346:2015 and is continuously
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THE POWER OF FASTENING
STEEL CONSTRUCTION INSTITUTE
hot-dip coated. EN 10346:2015 includes a range of possible metallic coatings and thicknesses. The most commonly used corrosion protection on strip steel used in the UK and Ireland is zinc galvanising Z275. The corrosion protection performance of Z275 is well understood and has been the widely researched, which is detailed in SCI publication P262 ‘Durability of Light Steel Framing in Residential Building Second Edition’. Z275 coating is also quoted as an acceptable corrosion protection in documents such as NHBC Standards Chapter 6.10 for Light Steel Framing. However, other coatings are available and some cold-formed steel product providers are considering using strip steel with the Magnelis® coating available from ArcelorMittal. The
Magnelis® coating is a ZM (zinc aluminium magnesium) coating in accordance with EN 10346:2015. The SCI has recently completed an independent review of the performance of the ArcelorMittal Magnelis® coating for corrosion protection. SCI was given access to the extensive research carried out by ArcelorMittal. Following the review, SCI’s conclusions and recommendations are; • Magnelis® ZM120 provides corrosion protection on the surface which is not less than the corrosion protection provided by Z275 coating. • Magnelis® ZM120 provides corrosion protection on uncoated cut edges which is not less than the corrosion protection provided by Z275 coated steel.
• Magnelis® ZM120 is suitable for the same applications as the Z275 coating which is typically specified in UK and Irish construction. • The design life predictions for the Z275 coating as stated in SCI publication P262 are also applicable to Magnelis® ZM120. The scope of the performance review carried out by SCI focused on the corrosion protection performance of Magnelis®, other characteristics such as cost, environmental credentials, aesthetics and fabrication were not included within the scope of works.
For more information visit: www.steel-sci.com
The full details of the SCI review are included in SCI Report RT1892 which is available at https://industry.arcelormittal.com/scireviewsmagnelis. More information on Magnelis® is available at https://industry.arcelormittal.com/magnelis For more information on an independent assessment by SCI of products or services please contact assessment@steel-sci.com
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LIGHTSTEELFRAMINGMAGAZINE.CO.UK
Leading offsite technology consultants
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DELIVERING A FAST RETURN ON INVESTMENT… Whilst improving safety, speed and performance through a systems-based light steel frame approach. Introducing Pre-Assembled Frames (PAF) Developed to eliminate uncertainty surrounding the design and specification of the external envelope and deliver crucial programme savings of up to 30%. CERTIFIED AND PREDICTABLE PERFORMANCE IN ONE UNITISED SOLUTION Pre-cut, prefabricated and preassembled offsite in controlled factory conditions, these non-loadbearing infill systems are delivered to site as an assembled panelised unit encapsulating EOS light steel framing and external Siniat Weather Defence boarding, ready for glass mineral wool insulation and Siniat internal wall linings to be fitted onsite. Combining the technical and manufacturing expertise of the Etex Group PAF provides:
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Fire tested to 60 minutes
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F I RE SAF E T Y F OR ST E E L F RA ME SYSTEMS SIDERISE is a market leader in the design and development of specialist passive fire protection solutions for the construction, façades and interiors sectors suitable for use with Steel Frame Systems. We have developed a wide range of firestopping products and systems that meet the requirements of current national building regulations for applications including ceilings and floor and wall compartmentation – with at least an equal fire performance rating to that of our Cavity Barrier or Fire Stop. Our fire safe insulation products provide the following benefits: • Proven in use with market-leading fire performance • Unique construction provides unrivalled movement performance • Third-party ‘Certifire’ approvals • Expert Technical support • Simple and quick to install with comprehensive training available.
Find out more about Siderise and our products at www.siderise.com We’re proud to be new members of the LSFA