precast MAY/JUNE 2023
DEDICATED TO THE DEVELOPMENT AND APPLICATION OF PRECAST CONCRETE
Strength on Every Level Putting Precast in the Picture
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PRECAST CONCRETE
MASS APPEAL
Familiar to all in the construction world and a mainstay of the offsite sector, precast concrete is at the centre of many landmark projects. This special section of the magazine highlights some of the awardwinning schemes where precast concrete has been used. particularly from low factory wastage thanks to reusable forms and volumes of batched concrete matched to need. In addition, its robustness and resilience mean less packaging is needed with large panels simply lifted straight off the delivery vehicle, ready for assembly on-site.”
1 Precast concrete is well understood for its structural strengths, solid reliable mass and its ability to suit a variety of applications and sectors – this is perhaps a central reason for its success. Precast concrete is not limited to a particular sector such as student accommodation or hotels but stands ready to provide stable solutions across the whole construction and infrastructure world. Of course, sustainability and low carbon design is of paramount importance in any construction programme and the concrete industry is working hard to reduce its embodied carbon levels and has embarked on a detailed decarbonisation programme led by companies such as Forterra and PCE – some of which you will see over the next few pages. As Elaine Toogood, Director, Architecture & Sustainable Design at MPA The Concrete Centre said recently: “The construction industry is developing a much greater understanding of carbon impacts across the entire lifecycle of buildings and materials, from embodied carbon at construction, to operational energy efficiency, to what happens at endof-life. Offsite concrete benefits
What can Precast Concrete Offer? Acoustically Versatile As precast can be moulded to any shape, size and texture it can be used to deflect or absorb noise. This makes it a good acoustic host for music but also an effective sound barrier alongside busy roads. Privacy and effective sound reduction are ensured, which makes precast an ideal choice for residential buildings. Architectural Precast concrete has the potential to be made in any shape. Moulds can be designed to be customised, replicate patterns, shapes or other materials. There are also many different aggregates and additions that can be incorporated into precast which gives designers considerable scope to produce subtle or contrasting colourways. Durable The factory-controlled production process means that cover to rebar is consistent and correct, as are strength and concrete quality. Hence the inherent durability of the delivered product is assured. Fireproof Precast protects against the spread of fire between rooms or buildings and it cannot catch fire, burn or drip molten particles. In test, concrete performs consistently well in fire, often requiring only minor repairs.
Strong Precast concrete goes on increasing its strength for hundreds of years after it is cast. What's more, during that time it won't shrink, warp, move or creep excessively so can be relied upon to perform consistently year after year. Sustainable All the materials that go into precast concrete products come from natural and recycled sources. This means they are subject to minimal processing or chemical treatments to render them suitable for use, which results in concrete having a relatively low embodied energy value. Thermally Efficient The versatility of precast can be seen in its application as a carrying medium for heating or cooling. As concrete can be dense or lightweight, precast concrete can act as a thermal sink or as an insulator and in some buildings, you can see precast doing both. Weather-proof Precast concrete is resistant to rain penetration and wind-blown debris. It can also withstand many winters of freeze-thaw cycles. The next few pages feature a range of case studies including: FP McCann, PCE, Carlow Concrete and Everton FC’s new stadium, plus a pioneering development in Finland that sees concrete and timber combining in a hybrid approach. For more information visit: www.mpaprecast.org Images: 01. Precast concrete panels are craned into position to make construction quicker and safer. Courtesy Creagh Concrete
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PRECAST CONCRETE
PRECAST TRANSFORMATIONS
Precast concrete specialists FP McCann have delivered many projects successfully including two landmark education schemes for York and Leicester Universities. The strong, simple forms of the precast concrete modular blocks, characterised by striking architectural finishes, have been designed to be a modern interpretation of the character of the university’s original 1960s campus.
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Working closely alongside Sheppard Robson and main contractor Graham, FP McCann were able to satisfy the requirement for the design and build project to fully embrace Modern Methods of Construction (MMC). The key elements of MMC include prefabricated insulated sandwich panels with integrated external brick faced, acid-etched and stencilled finishes, factory fitted windows, first fix services and factory finished internal walls and ceilings. Sub-contractor to FP McCann, Ulster based precast concrete installation specialist McVey Stone, has constructed the 18-block precast modular buildings in just 58 weeks. The offsite manufactured precast concrete crosswall/insulated sandwich panel system was specified on the build to enhance quality, safety and sustainability. Construction times were reduced by up to 60% and significant other benefits associated with MMC such as reduced wastage and allweather working were achieved.
2 FP McCann's Precast Off-Site Building Products Division has worked in close partnership with national construction group Graham on the construction of a 1,480 bed student accommodation project – part of York University’s ‘Campus for the Future' masterplan. The £130million flagship scheme to help transform the Heslington
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East Campus commenced in 2019 and completed ahead of the 2022 academic year. Architect on the project Sheppard Robson, designed the residential development in a natural waterside setting which has been broken down into 18 blocks that step down from four to three storeys in height as they get closer to the waterfront.
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FP McCann has manufactured and delivered a total of 7,177 individual precast concrete units for the internal structural frames and the cladding envelopes, including walls, floor slabs and external architectural sandwich panels. Additionally, and included in the supply contract, are precast stairs and landings, precast concrete columns and architectural cladding to support steels on all overhang areas. The internal crosswall sections are 160mm, 180mm and 200mm thick and
PRECAST CONCRETE the external sandwich facade panels are 465mm thick. The inner leaf of the sandwich panel is typically a 150mm thick structural concrete skin designed to carry its own dead loading and that of the external skin. Insulation between the concrete faces is 200mm thick and the outer concrete/brick façade 115mm. The facade skin of the sandwich panels is a combination of half brick and projecting full solid bricks, acid-etched smooth concrete finish and an acid-etched architectural stencilled design, created using the Reckli rubber formliner system. The precast units were manufactured at FP McCann’s Byley, Littleport and Grantham manufacturing facilities and delivered on a just-in-time basis. Commenting on the build Special Projects Director for Graham, Neil McFarlane says: “We adopted the FP McCann offsite modular precast concrete building system for our construction programme, as we recognise it is a well tried and tested methodology that brings enhanced quality and delivery confidence to such ambitious residential development schemes. The consortium of companies has delivered innovative, energy efficient and sustainable living to support student and University growth at York.” Leicester University FP McCann also worked in collaboration with regeneration and facilities management company Equans on the £200million contract to build student accommodation at the Freeman’s Common Student Village, part of Leicester University. The flagship scheme includes seven residential blocks, a 550-space multistorey car park and the creation of a new 9,000sq m teaching and learning centre. Architect on the project Sheppard Robson designed the residential development that was completed in 2022. The regeneration of the site which includes refurbishment of the historic Grade 2 listed Freeman’s Cottages creates a new gateway link through to the city centre. Working closely alongside Sheppard Robson and managing build partner/ client Equans, FP McCann’s engineers and supply/install teams were able to satisfy the requirement for the design and build of two of the
3 seven residential blocks whilst fully embracing MMC. The key elements of MMC on the project include prefabricated insulated sandwich panels with integrated external brick faced and acid-etched finishes, factoryfitted windows, first fix services and factory finished internal walls and ceilings. The offsite manufactured precast concrete crosswall/insulated sandwich panel system was specified on the build to enhance quality, safety and sustainability. Construction times were reduced by up to 60% and significant other benefits associated with MMC such as reduced wastage and allweather working were achieved. FP McCann has manufactured, delivered and installed around 6,000 individual precast concrete units for the internal structural frames and the cladding envelopes, including walls, floor slabs and external architectural sandwich panels. Additionally, and included in the supply contract, were precast stairs and landings. The internal crosswall sections are 160mm & 200mm thick and the external sandwich facade panels are 535mm thick (including a 100mm architectural fin detail). The inner leaf of the sandwich panel is typically a 150mm thick structural concrete skin designed to carry its own dead loading and that of the external skin. Insulation between the concrete faces is 150mm thick and the outer concrete/brick façade 135mm. The facade skin of the sandwich panels is a combination of half brick and acid-etched smooth concrete finish. The precast units
4 were manufactured at FP McCann’s Grantham manufacturing facility and delivered on a just-in-time basis. Commenting on the build, Jake Fellows, Development Director (Places and Communities) for Equans said: “We adopted the FP McCann offsite modular precast concrete building system for our construction programme, as we recognise it is a well tried and tested methodology that brings enhanced quality and delivery confidence to such ambitious residential development schemes. The consortium of companies and designers has delivered innovative, energy efficient and sustainable living to support student and University growth at Leicester.” For more information visit: www.fpmccann.co.uk Images: 01-02. York University, Heslington East Campus 03-04. Leicester University, Freeman’s Common Student Village
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CASE STUDY
PRECAST CONCRETE
RE-ENERGISING PRISON ESTATES
1 Precast concrete has a huge role to play in the construction of new prisons and revitalising the UK’s custodial estate. One project at HMP Millsike, York will also see the development of the UK’s first ‘all-electric’ prison. The new prison – opening in 2025 – will hold nearly 1,500 prisoners with the site set to be the first prison in the UK to run solely on electricity, with solar panels and heat pump technology meaning it will use 78% less energy than HMP Wormwood Scrubs – a traditional Victorian prison – cutting energy costs to taxpayers by over £1.1million a year. HMP Millsike – situated on land opposite the existing HMP Full Sutton – has been named after Millsike Beck, a local river that runs adjacent to the new jail. The building project is also set to boost jobs in East Yorkshire, with a quarter of those working on the build and 40% of the construction spend falling within 50 miles.
2 Through applying the findings of the government-sponsored Decarbonisation of Precast Concrete study, PCE have established and implemented carbon-reduction solutions on HMP Millsike – currently in construction – achieving a 12% reduction in embodied carbon when compared with HMP Fosse Way, constructed in 2021. Working with multiple manufacturers across the supply chain, PCE collaboratively reviewed, innovated and tested mix designs, ensuring the revised mix design would continue to deliver structural integrity and other required performance properties, whilst simultaneously achieving a reduction in carbon content. The 12% reduction achieved translates to a saving of over 1,200 tonnes of CO2 with an actual average of 443kg e/m³ against the HMP Fosse Way project of 501kg CO2/m³. In other words, the new prison at Full Sutton has seen a reduction of over 753kg CO2 per prison place.
PCE Ltd has been appointed by Kier as its superstructure and façade delivery partner, with the Ministry of Justice project having an overall contract value of £400million. This once again sees PCE’s award winning HybriDfMA Secure Prison System being used following the successful completion of HMP Five Wells, at Wellingborough and HMP Fosse Way, Glen Parva.
When scaled up across the Government’s entire new prison programme, these savings alone would result in a saving of over 15,000 tonnes of CO2. By transferring this knowledge across the other PCE systems and other sectors, the impact can truly and fundamentally help revolutionise the construction industry.
The plan is for HMP Millsike to operate as zero-carbon in the future, with an all-electric design, solar panels, heat pumps and more efficient lighting systems to reduce energy demand significantly. The new buildings will sit adjacent to the existing HMP Full Sutton and is part of the Government’s plan to create thousands of new prison places.
The research project based on PCE’s solutions for both the HMP Five Wells and HMP Foss Way prisons, developed an optimised structural design and concrete mix technical specification improving material efficiency and delivering a net reduction of up to 40% in the structural precast concrete’s embodied carbon emissions, when benchmarked against the ICE’s database.
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“Through leveraging Hybrid DfMA and an offsite ‘kit of parts’ philosophy, we do not just embrace modern methods of construction, but revolutionise it,” said Simon Harold, Business Development Director at PCE. “This coupled with our shared commitment for continuous improvement with our partners, will help facilitate continued practical progress in a more environmentally friendly, structurally robust and commercially sound approach to design and build.” Liam Cummins, Group Managing Director of Kier Construction, said: “We will deliver this new prison as a cutting-edge facility, built on engineering excellence that we have utilised on other projects, and using innovative sustainable methods which will achieve net zero in operation. Alongside this, we’ll create hundreds of jobs throughout the lifecycle of the project, supporting local people and the supply chain, as well as providing opportunities for prisoners on release.” The new site will set a gold-standard for energy efficiency – set to use 68% less energy from the national grid than even the newly-built HMP Five Wells in Wellingborough and draw 18 GWh less energy from the electricity and gas networks every year than HMP Belmarsh – which is equivalent to powering 1,200 homes for a year. For more information visit: www.pceltd.co.uk www.kier.co.uk Images: 01. PCE team on-site at HMP Millsike. Courtesy PCE Ltd 02. Decarbonisation is hugely important to the concrete sector. Courtesy Akerlof
CASE STUDY
PRECAST CONCRETE
MANCHESTER AESTHETICS
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Manchester Goods Yard is the fulcrum for Enterprise City, a new digital media technology hub in Manchester city centre that has used precast concrete to provide stunning new work and leisure facilities. Architects Chapman Taylor paid attention to detail and reflected Manchester’s industrial vernacular as key factors in ensuring this scheme's context. They were able to define the design, assembly, logistics and quality at a very early stage which also included the installation of the windows in the factory, in factory conditions to create a complete modular assembly ready for hanging on the building. The ultra-modern, flexible workspaces will be supplemented by a mix of café bars, restaurants and leisure facilities, with the aim of creating a vibrant neighbourhood in which to live, work, shop and relax. Manchester Goods Yard (MGY) is a significant new office scheme at the heart of the St. John’s regeneration development, a new city centre neighbourhood underpinned by enterprise, culture and living. Techrete precast panels were used that are 100% recyclable at the end-oflife stage fulfilling the futureproofing and circular economy approach. Techrete also promotes the use of partial cement replacement in their mixture to minimise embodied carbon impact. The collaborative offsite approach between the façade suppliers meant that the overall embodied carbon implication from transport was significantly reduced. Each panel provides a deep concrete reveal – vital in emphasising the industrial aesthetic. The 400mm thick precast concrete panels with 200mm mineral wool insulation behind them
3 provides a betterment against current Part L U-values. Offsite manufacture enabled cost certainty, as materials are quantifiable, and less wastage occurred due to the production process. A mix of construction techniques were used for the building superstructure. The two satellite cores were constructed with twin-wall precast concrete panels and the main core was cast in-situ. This hybrid approach allowed areas of the building to be accelerated to improve commercial viability, and to improve programme by allowing different disciplines to safely work on elements at different phases and stages of the building. The façade subcontractors, Lindner Prater and Techrete worked collaboratively to facilitate the installation of the curtain wall systems into the precast concrete panels at the Techrete’s factory before being transported to the construction site. This benefitted offsite manufacturing processes – e.g. waste mitigation and controlled quality, and importantly lessened the number of lifts that were required by combining two separate components. The level of automation, factory consistency and quality provided by the offsite manufacturing process of
the precast panels ensured consistency in the appearance, performance, and finish. The precast panels have increased lifecycle capability with minimal maintenance required due to their durability. No applied finishes were added to the exposed concrete, reducing maintenance requirements whilst evoking an industrial feel in a contemporary environment. The precast concrete donut panels have been designed to interlock into one another for both ease of assembly and future disassembly. MGY is rated BREEAM Excellent and used offsite manufacture and assembly to maximise opportunities to reduce waste, improve quality and minimise its carbon footprint. This innovative approach to designing new office space has provided c.31,000m² of shell and core commercial space across 10 floors, two levels of basement parking and cycle facilities. For more information visit: www.chapmantaylor.com www.techcrete.com Images: 01-03. Precast concrete has given a contemporary feel to Manchester’s latest multi-purpose commercial project
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ADVERTORIAL
TRIED & TRUSTED PRECAST SOLUTIONS
Carlow Concrete are the market leader in water retaining precast concrete structures in both the United Kingdom & Ireland – what do they provide?
1 The flagship product of Carlow Concrete is the Carlow Tank. Recognised by both water companies and councils, our stormwater attenuation system satisfies mandatory SUDs requirements and is fully S104 adoption compliant. In terms of stormwater attenuation, the Carlow Tank offers clients the most efficiently and economically designed solution in its class. This attenuation powerhouse promises the most robust solution on the market and may be located in highly trafficked areas such as roads and carparks. Design, innovation, accreditations and approvals Carlow Concrete prides itself on continuous design innovation and improvement. At design stage each project undergoes rigorous structural design using cutting edge analysis software and the option of 3D building information modelling (BIM) modelling at both approval and construction stages. The extensive design service is implemented by a highly qualified design department which consists of civil, structural, environmental and process design engineers. Our design department also maintain our innovation centre in terms of research and development which are very important to the group. Carlow Concrete are the only precast supplier to design out flotation issues and fully comply with BS8007 and Eurocode II.
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2 Production and experience As part of the Burren Precast Concrete Group, Carlow Concrete has the resources and infrastructure to meet the high demands of their customers in relation to quality of service and product. The organisation benefits from a team with combined expertise of over 100 years in the precast industry. Carlow Concrete has technical expertise, flexibility in production methods and the resources to interpret, design, manufacture and assemble to the highest standards in meeting the requirements of every project, bringing modern methods of construction (MMC) through the benefits of offsite construction, BIM and highly experienced installation teams. Why Carlow Concrete stormwater attenuation tanks? At Carlow Concrete a key ingredient of quality production are our technicians and in-house concrete testing lab. To back this up in delivering the best possible stormwater attenuation solution an ID tag provides each element of an installation with its own unique reference number so it is fully traceable from production to final location. Here are some of the features and benefits of the Carlow Tank. • Available in depths from 0.8M to 7.0M in 100mm increments • Configured to exactly suit client requirements including irregular shapes
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• Modular precast attenuation/ detention tank which satisfies clients mandatory Sustainable Urban Drainage (SUDS) requirements • Most cost effective storm water attenuation solution on the market • Watertight to BS8007 or Eurocode 2 • Fully section 104 adoptable • CESWI & Sewers for adoption compliant • 100 Year + Design Life • No need expensive imported fill or waterproofing, simply backfill as dug material • Rapid installation times from highly trained, experienced crews • Reduction in labour and plant requirements during install • Deep burial and heavy duty loading applications • Superior quality finish and zero maintenance • Multifunctional applications • Trusted by top companies across the construction industry. Design, manufacture, deliver and install – your turnkey solution Carlow offer a range of flexible models to our clients, the most popular being that of a Procurement Framework Agreement. Many clients have taken full advantage of this approach when ordering the same service over an extended period of time on multiple projects and across several regions. This supply framework is an ideal platform where the client has a real focus with us to develop a strategic long term relationship which ultimately offers a sustainable, best value supply chain for precast concrete attenuation/ flood alleviation products. For more information visit: www.carlowconcrete.com Images: 01-02. Precast concrete offers a premium solution to the design and delivery of stormwater attenuation systems
PRECAST CONCRETE
DECARBONISATION FOR BETTER BUSINESS
In some quarters, concrete comes in for much criticism for its lack of sustainability credentials compared to competing materials, but there are many innovative moves being made by industry with low carbon and circularity in mind. THE CIRCULAR CEMENT VALUE CHAIN A circular economy of concrete and cement could produce €110billion in net value and avoid or mitigate two billion tons of CO2 emissions by 2050, according to a new McKinsey & Company report. As the new report spells out, cement and concrete are the ‘linchpins of the built environment’ with its global demand having nearly tripled over the past 20 years. With circular economy principles driving much sustainable thinking, what decarbonisation principles are at stake? The ‘Circular cement value chain: Sustainable and profitable report’ projects that adoption of circular technologies could also decarbonise 80% of all cement and concrete emissions by 2050. This will be driven by capture, storage and usage of CO2 from cement and concrete production, re-use of energy from waste material and recirculation of materials and minerals across the built environment. Adoption of circular economy principles is estimated to offset more than half of the losses to the cement industry from rising costs and reduced demand. And adoption of circular technologies could be further accelerated by rising CO2 prices, landfill costs and decarbonization subsidies. The report reveals that recycling and re-using construction materials and minerals alone will add nearly €80billion of annual EBITDA while reusing concrete modules and structures will drive an estimated €24billion of net value by 2050. Regions with high landfill costs and construction and demolition waste will also reap major benefits from the use of alternative fuels from waste material with the global average share of alternative fuels reaching 43% by 2050. Sebastian Reiter, Partner at McKinsey's Global Energy & Materials adds: “Cement and other industry players should engage in circular business building and use circular technologies to react to evolving financial risks. The total value at risk from rising CO2 prices and landfill costs could reach approximately €210billion by 2050 and this will significantly accelerate uptake of circular technologies. For example, our research shows that technologies utilising CO2 such as curing ready-mix or precast concrete can create positive economic value at carbon prices of approximately €80% of CO2 while using construction waste as aggregates for concrete production avoids landfill costs.” Central to all future behaviour is increasing customer centricity will likely create new opportunities across the built environment. New business models for all players in the built environment—not only cement and concrete manufacturers—are expected to evolve from actions that facilitate circularity along the value chain as well as actions that deliver the value of circularity to consumers. For more information visit: www.mckinsey.com
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Ibstock and Earth Friendly Concrete form partnership to support ESG ambitions Ibstock, a UK leading manufacturer of clay and concrete building products, and Earth Friendly Concrete (EFC) have entered into a new partnership to create ultra-low carbon concrete products. This exciting partnership supports Ibstock’s ambitious ESG targets. Having recently launched its ESG Strategy to 2030, Ibstock is committed to ‘Manufacture Materials for Life’ and improving the environmental performance of its products. Its milestone 2030 target is to achieve 20% of sales turnover revenue from new and sustainable products. With the built environment accounting for 25% of the UK’s carbon emissions, Ibstock is proactively seeking to develop new solutions with improved environmental performance. EFC is more sustainable than traditional concrete, with around 70% less embodied CO2 saving 250kg of CO2 per cubic metre poured. It is made from a binder consisting of industrial waste products, ground granulated blast furnace slag and pulverised fly ash with no Portland Cement. The partnership will see EFC’s ultra-low carbon, zero
PRECAST CONCRETE cement technology integrated into Ibstock’s diverse portfolio of highperformance building products for the construction industry, including its range of products for the rail, infrastructure and UK housing markets. The technology has performance advantages over Ordinary Portland Cement-based products including improved durability, lower shrinkage, higher flexural tensile strength and increased fire resistance and is the only zero-cement concrete technology that has been proven at scale on real life commercial projects across the world. Darren Waters, Chief Operating Officer at Ibstock, said: “As a business at the heart of building, our ambition is to be the most sustainable manufacturer of concrete products in the UK. Collaborating with EFC marks a significant step in achieving this goal as we collaborate and innovate to manufacture materials for life. More than ever, customers are looking for products which offer great functionality but also have robust sustainability credentials. In 2020, the Ibstock concrete division invested in a new concrete laboratory at its site in Anstone, Sheffield, to facilitate the development of sustainable concrete that features reduced embodied carbon and therefore has a lower environmental impact. At this advanced facility, we are already developing and testing innovative new concrete mixes that incorporate EFC to ensure we achieve our own sustainability goals, as well as contribute to those of the wider sector, without compromising on quality or performance.” EFC UK Regional Manager Andy Izod said: “We are delighted to strengthen our presence in the UK through this partnership with Ibstock. We will not only focus on introducing Earth Friendly Concrete into the wider construction market across a range of projects, regions, applications and supply chains but will also share our ground-breaking technology with partners like Ibstock, which will help them to achieve ultra-low carbon outcomes for their business.” Since it was launched in 2020, EFC has saved around 2,000 tonnes of CO2 across construction projects. It has been used in several high-profile projects including High Speed 2 (HS2) and Silvertown Tunnel. For more information visit: www.ibstockplc.co.uk www.earthfriendlyconcrete.com
LOW CARBON CONCRETE NOW STANDARD ON LAING O’ROURKE UK PROJECTS Laing O’Rourke has announced it is mandating the switch to low carbon concrete on all of its new UK projects. The exclusive use of low carbon concrete from 1 April this year will accelerate the company’s progress towards its net zero targets. The change will be introduced with immediate effect and applies to all new projects that begin main construction on or after 1 April 2023. It will result in a significant reduction in the company’s scope 3 carbon emissions. Following a long-term research programme co-funded by Laing O’Rourke and Innovate UK, and in collaboration with the University of Cambridge and Sheffield University’s Advanced Manufacturing Research Centre (AMRC), the business has proven that a range of low carbon concrete options can be successfully deployed on projects as a like-for-like substitute for traditional concrete. The overall carbon reduction will be 28% when compared with the company’s concrete usage in 2022. This equates to a saving of 14.4 million kgCO2e, which is the same as planting 120,000 trees or 94 hectares of forest. Cathal O’Rourke, Laing O’Rourke’s newly appointed Chief Operating Officer, said: “We’ve committed to being a net zero company before 2050 and we are looking at every possible measure to accelerate our progress. In construction, the greatest challenge is reducing scope 3 emissions – the embodied carbon in purchased materials. Reducing all carbon emissions is a priority for our business. The built environment makes a significant contribution to global warming and constructors must work with clients and design partners to deploy new technologies and innovations that make modern methods the norm and enable us to build in less carbon intensive ways.” Rossella Nicolin, Laing O’Rourke’s Head of Sustainability for Europe, said that the expertise of the specialist businesses that make up the company’s internal supply chain had helped introduce the policy so rapidly across all new projects. “The expertise of our in-house concrete technologists, the experts who operate our advanced manufacturing facility in Nottinghamshire (the Laing O’Rourke Centre of Excellence for Modern Construction, CEMC), and our supply chain partners, have all contributed to this significant step forward. Last year, 43% of the concrete products we manufactured for our live projects were low carbon. It’s exciting to think this will rise to 100% this year, and that very soon all our new projects will only use low carbon concrete. I want to thank the team whose hard work has made it possible.” Laing O’Rourke’s low carbon concrete uses lower carbon alternatives to Portland cement. These include GGBS (Ground Granulated Blast-furnace Slag) and PFA (Pulverised Fly Ash), both of which are industrial by-products with a much lower carbon footprint. The company recognises that this is the first step in a longer journey to decarbonisation. Its ongoing research programme focuses on wider scale deployment of cement-free options, which are ultra-low carbon, and it expects to introduce more of these materials going forward. The company became a founding member of ConcreteZero in 2022 and is already decarbonising beyond the programme’s near-term objectives. For more information visit: www.laingorourke.com
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PRECAST CONCRETE
MASTERING WHISKEY STORE CONSTRUCTION Constructing a whiskey store is a delicate affair. As O'Reilly Precast appreciate, the significance of selecting the right materials is essential and precast concrete has proven to be a superior option, offering a wealth of benefits for whiskey store projects. Precast concrete has consistently demonstrated its value in constructing whiskey stores that withstand the test of time. Discover the key advantages of using precast concrete in whiskey store construction: Temperature and Humidity Control: precast concrete ensures excellent insulation, maintaining consistent conditions crucial for top-notch whiskey maturation.
Fire Resistance: with flammable materials in whiskey stores, precast concrete’s fire-resistant properties offer added safety and reassurance. Durability and Strength: precast concrete guarantees a long-lasting structure, capable of bearing the weight of whiskey barrels. Pest and Rodent Resistance: unlike other materials prone to infestations, precast concrete safeguards hygiene and quality. Design Flexibility: customised to meet specific requirements, precast concrete is the ideal choice for bespoke whiskey maturation facilities. Speed of Construction: offsite manufacturing allows for efficient construction, reducing costs and minimising disruptions to ongoing operations.
Ready to enhance your whiskey store construction with the precast concrete advantage? Contact our team of experts at O'Reilly Precast to discuss your project needs. Phone: 0121 630 3472, email: sales@oreillyprecast.co.uk, or visit: www.oreillyprecast.co.uk
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PRECAST CONCRETE
A WINNING COMBINATION
Although competing materials on many levels, concrete and timber can combine to provide sustainable hybrid building solutions that will be evidenced by some pioneering developments in Finland.
1 Finland's leading precast concrete element manufacturer Consolis Parma, housebuilder Arkta Rakennus and Metsä Wood – one of Europe’s leading manufacturers of engineered wood products – have launched a research project on hybrid construction that promotes low-carbon construction. The aim is to develop a completely new kind of construction concept mainly for the needs of residential multi-storey construction, which will reduce the environmental impacts of construction by utilising hybrid structures. The sustainable development of the construction industry focuses on energy and material efficiency, as well as low-carbon construction and the circular economy. “Radically cutting the climate impact is a common concern for the entire construction industry,” says Juha Rämö, Technology
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Director at Consolis Parma. “In line with our strategy, we have put climate issues at the centre of our development work, and our goal is to reduce our emissions by 5% annually and halve them by 2035. “In terms of the climate impacts of the built environment, the transition from fossil fuels to renewable energy means that the influence of the actual construction phase in the building's lifecycle emissions will increase. As a result, structural solutions and the material choices in construction will play an increasingly crucial role in reducing the climate impact of the construction phase in the future. “We have launched a whole product family of low-emission concrete products that can significantly reduce material-based emissions from construction. In this research project,
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we are looking for new ways to reduce even more material emissions by utilising new hybrid structures and the best properties of different materials.” The aim of the partnership between Parma, Arkta and Metsä is to create a material-efficient and low-emission hybrid construction concept. In this context, hybrid construction refers to combining the best features of timber and concrete both in a building frame and façade solutions to make the building low-carbon, energy-saving, long-lasting and cost-effective. "Hybrid construction enables increasing the share of renewable material in multi-storey construction without compromising building process efficiency or the performance of solution,” says Jussi Björman, Director, Business Development Construction at Metsä Wood. “Metsä Wood's lightweight, material-
PRECAST CONCRETE
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efficient and carbon-storing Kerto® LVL engineered wood product is well suited for hybrid construction applications. In co-operation with our partners, we have the best prerequisites for finding the most effective overall solutions.” The structural solutions being developed as part of the research project will be tested in an apartment building project in Finland. “We are an expert in both concrete and wood construction and we know very well how these two different building materials behave. By utilising this know-how, our goal is to together develop solutions that combine the best properties of wood and concrete with the new hybrid construction system," says Marko Nikander, Technical Director at Arkta Rakennus. “We act as an expert of the construction site and installation process. We want to ensure the development of functional hybrid solutions using the best expertise of the project parties. The end goal of the research project is to produce costeffective and easily replicable lowcarbon hybrid element structures that create a brand new way of building both in Finland and around the world.” For more information visit: www.metsagroup.com Images: 01-02. Concrete and timber will combine to provide a long-term hybrid panel product. 03. Kerto LVL are part of the hybrid sandwich timber elements 04. Thanks to their special design and structure, DURAForm formwork panels allow for considerably leaner and resource-saving formwork structures and easy handling on-site
4 MORE CONCRETE & TIMBER SOLUTIONS Formwork systems give precast concrete its ‘form’ allowing for quick project delivery. As an aid Metsä Wood has expanded its range of formwork panels with DURAForm. The DURAForm formwork panel line features high stability and reduced deformation, despite its reduced weight. The long-lasting maintenancefree birch plywood panels are very easy to work with and provide an especially smooth concrete finish thanks to their special surface. Produced from high-strength birch plywood, the material offers minimal deflection, even with wide spans. Despite its low weight, DURAForm demonstrates especially high strength. Thanks to the special design and structure, the panels allow for considerably leaner and resource-saving formwork structures and easy handling on-site. Concrete formwork is heavily stressed during use at construction sites. In this context, the hard scratch-resistant composite surface of the Metsä Wood DURAForm elements makes cleaning and later reuse of the panels easy. The improved crack resistance and reduced chipping, even when fastening using nails, contribute to a consistently high surface quality. Since they can be reused up to 200 times, the DURAForm panels have proven to be particularly resource-friendly beyond their lifecycle in line with the principles of a sustainable circular economy.
MAY/JUNE 2023 | WWW.PRECASTMAGAZINE.CO.UK
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PRECAST CONCRETE
LOOK OUT FOR NEW MINERAL TRENDS
The Mineral Products Association (MPA) has published a new regional construction and mineral products markets report, giving a detailed assessment of historic, current and future trends across every region of Great Britain.
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1 Primarily prepared to help inform and support the local mineral planning system, the annual report compiles a range of industry data and broader context to paint a clear picture of the main drivers of activity in heavy-side construction materials and industrial minerals – it’s an essential tool for producers and planners alike. The report includes summaries for all regions and devolved administrations in Great Britain, illustrating the recent performance of construction and mineral products markets, with critical insight on the sectors that are expected to drive growth in mineral products demand over the next five years (2023-27). While London is often regarded as the key hub of new construction projects and infrastructure, representing 21% of the total value of construction output in 2022, the report highlights that the East of England and Yorkshire and the Humber are both expected to see the fastest rate of growth (2.2%) over the next five years, led by energy-related projects. 16
Data on mineral products sales volumes is collected through a rigorous survey process among MPA producer members, who make up the vast majority of the total mineral products markets, including 90% of total GB market sales for primary aggregates and asphalt, for example, and 75% for ready-mixed concrete. The report reveals that construction demand for mineral products in 2022 recorded a gradual loss in momentum as the year progressed on the back of a worsening macroeconomic environment and slowing activity in key segments of construction. Tonnages of primary aggregates sales fell by 8.2% on an annual basis compared to 2021, asphalt by 6.5%, and ready-mixed concrete by 3.8%. The East Midlands was the biggest market for asphalt and crushed rock in 2022, accounting for 15% and 29% respectively of total sales in Great Britain. It is also the region that emerged as the most resilient to the downturn last year, recording the smallest falls in demand. Meanwhile, London was the biggest centre of demand for ready-mixed concrete, accounting for 19% of total sales volumes from fixed plants. Demand in London last year remained broadly flat, in contrast to the 5.5% decline recorded at national level.
WWW.PRECASTMAGAZINE.CO.UK | MAY/JUNE 2023
Luke George, Economist at MPA and author of the report, said: “This new report provides a valuable insight to the contrasting dynamics in construction and mineral products markets across the various regional and devolved administrations of Great Britain. Our aim is to provide a unique, easy-to-use point of reference to support MPA members, planning professionals and other industry experts in their decision-making processes. This report cuts through the overwhelming quantity of industry data that’s available and revised almost daily. “Minerals, and the wide range of construction products that are derived from them, are key elements to the successful delivery of many of Government’s ambitious policy objectives, such as on housing and infrastructure, including achieving the energy transition and delivering net zero. The success of the UK economy to deliver on these objectives will depend on local mineral planning authorities and mineral producers having robust evidence around future market needs, given delivery is heavily reliant on the availability and supply of essential mineral products.” The report ‘Regional overview and forecasts of construction and mineral products markets in Great Britain Spring 2023’ can be downloaded at: www.mineralproducts.org
Images: 01. The new report outlines what can be expected across the concrete, masonry and mineral sectors 02. Precast concrete is a staple product of countless drainage and infrastructure projects
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STADIUM DESIGN
PRECAST: THE HEART OF MODERN STADIUM DESIGN
Precast concrete has been a star player in the construction of sporting venues around the UK. One, perhaps obvious appeal, is precast concrete’s robustness and durability.
1 Almost every football and rugby ground, athletics stadium and indoor arena features some form of precast component, as does much of the associated infrastructure. “Of particular concern in stadium design is the effect of resonant frequency, when a structure moves due to the dynamics of crowd movement,” explains Elaine Toogood, Director, Architecture & Sustainable Design with The Concrete Centre. “The use of concrete is widely understood to limit this.”
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has already won numerous accolades with its eye-catching design, brilliantly blending the modern with the traditional. Nothing exemplifies this better than the precast concrete structure and terraces, a solution used in stadium design for decades but now deployed with all the benefits of MMC.
stadium. Using Building Information Modelling (BIM), the digital version of the stadium has been mapped out in intricate detail. The model includes everything from the precast concrete walls, through to precise positioning of wiring, plumbing, light switches and plug sockets.
This was why precast sections were a safe choice for the terraces on iconic venues like the London Olympic Stadium. In all, 9,250m³ of reinforced precast concrete was used within the Olympic Stadium bowl and more than 12,000 precast elements were required for the seating steps alone. Besides terrace units, other precast components typically used on stadia include raking beams, staircases and step blocks, vomitory walls, hollowcore slabs, flooring and cladding panels. Modern Methods of Construction (MMC) in the precast concrete sector are now enabling the next generation of stadia.
The stadium is scheduled for completion in 2024, but the primary concrete structure in all four stands is now complete. Precast concrete elements were produced offsite ready to slot together to form the floors, walls and supporting pillars of the stands. Each component was created in a specialist factory and brought to site using the modern digitally enabled process known as Design for Manufacturing and Assembly (DfMA). It is precast concrete which will also put bums on seats with 1,217 terracing units, forming the internal bowl lining. The bespoke, double-stepped terracing units manufactured by Banagher Precast Concrete in Ireland and delivered by boat to Liverpool docks, were lifted and bolted into place by the construction team from Laing O’Rourke.
This digital approach allows for efficiency gains, risk reduction and leads to programme and cost benefits. It also provides a digital reference throughout the lifecycle of the build allowing for easier design of extensions or repairs. Concrete MMC also enables the linking of a model to the construction programme, the construction team can visualise the construction sequence and assess potential risks or clashes in the programme. This programme optimisation can then feed into just-intime delivery and a faster build overall.
Everton Stadium Takes Shape Currently rising up from the banks of the river Mersey, Everton Football Club’s new 52,888-seater stadium
Laing O’Rourke have stated that upon completion Everton Stadium will have a real ‘wow’ factor having already created a virtual model of the
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WWW.PRECASTMAGAZINE.CO.UK | MAY/JUNE 2023
For information on how precast concrete is shaping the UK construction sector visit: www.mpaprecast.org Images: 01-03. The use of precast concrete is widespread across sporting arenas everywhere including the new stadium on the banks of the River Mersey for Everton football club. Courtesy Everton F.C
Ensuring high quality modern methods of construction Find out more at www.mpaprecast.org
Sophisticated manufacturing and quality control procedures mean concrete MMC techniques deliver a high quality, robust and reliable product every time. Modern digital construction practices are repeatable, reliable and traceable throughout the asset life-cycle. Significant time savings can be achieved by using concrete MMC solutions, from just-in-time delivery through to faster build programmes.
MPA Precast, Glenfield, Leicestershire LE3 8DG Web www.mpaprecast.org Twitter @mpa_precast
LinkedIn @mpaprecast
Image credit © levittbernstein.co.uk
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