Offsite Magazine - Issue 40

OFFSITE DEDICATED TO OFFSITE DESIGN, MANUFACTURE & DELIVERY | ISSUE 40 NOV/DEC 2023 | £4.95

ACHIEVING NET ZERO SCHOOLS DELIVERING AMBITIOUS ENERGY EFFICIENT TARGETS WITH PANELISED DESIGN

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ROBOTIC PRODUCTION We take a look inside British Offsite’s new, state-of-the-art Horizon facility

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BUILDING A DIGITAL FUTURE A roundtable hosted by Graitec discussed transforming construction via technology

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MEP What offsite methods can bring to this critical aspect of our built environment

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WELCOME

PUBLISHING

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FRONT COVER Innovaré Offsite Image: Bowmer + Kirkland/@bandkphoto PRINTED ON: FSC Mix paper

by Buxton Press PUBLISHER: Offsite Magazine is produced and published by Offsite Media Ltd 101 Longden Road, Shrewsbury, Shropshire, SY3 9PS T: 01743 290001 www.offsitemagazine.co.uk ©Offsite Media Ltd. SUBSCRIBE TO RECEIVE OFFSITE: This magazine is a bimonthly publication and the annual subscription fee for UK postage is £29.70 plus VAT for all six issues (£4.95 per copy). Visit www.offsitemagazine.co.uk ADVERTISING ENQUIRIES PLEASE CONTACT: Robert Aitken // T: 01743 290013 E: robert.aitken@offsitemagazine.co.uk SEND US YOUR NEWS: Gary Ramsay // T: 01743 290001 E: gary.ramsay@offsitemagazine.co.uk BACK ISSUES VISIT: www.offsitemagazine.co.uk FOR OFFSITE ENQUIRIES PLEASE CONTACT: E: info@offsitemagazine.co.uk DISCLAIMER: The content of Offsite 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. The publisher does not accept any liability of any loss arising from the late appearance or non-publication of any advertisement. Content including images and illustrations supplied by third parties are accepted in good faith and the publishers expect third parties to have obtained appropriate permissions, consents, licences or otherwise. The publisher does not accept any liability or any loss arising in the absence of these permissions for material used in both physical and digital editions. No part of this publication may be reproduced or stored in a retrieval system without the written consent of the publishers. All rights reserved.

Welcome to the last issue of Offsite Magazine for 2023. It has been a strange year for offsite in many respects as the sector has undoubtedly gone through a period of reflection with notable high-profile casualties over recent months - albeit in the volumetric modular space.

These do unfortunately cast a negative light on MMC. Speaking to the Built Environment Committee inquiry ‘Modern Methods of Construction – what’s gone wrong’ in October, Carl Leaver, Chairman of TopHat was vocal on the recent upheavals and inconsistencies amongst offsite providers. But the main thrust of the conversation was that it will be virtually impossible for the Government to attain its 300,000 homes a year target without the speed and efficiency that modular methods provide.

As we went to press TopHat agreed a £15million debt facility with Homes England via Homes England’s Levelling Up Home Building Fund – which supports innovative developers to build more homes. According to Peter Denton, Chief Executive of Homes England, this funding will support TopHat to manufacture more than four times the number of new homes it currently can each year, significantly increase the delivery capacity of the UK’s MMC sector and create 1,000

jobs. As TopHat gets closer to opening Europe’s largest modular housing factory in Corby next year, there will be enormous interest on its progress in 2024.

Speaking of housing – a personal bugbear – and for many others I suspect, was the appointment of another Housing Minister. As widely reported, Lee Rowley MP is now the 16th in 13 years. This relentless churn of representation helps nobody. The revolving door offers no continuity of thinking, little clear direction and housing support being at the mercy of the personal interest – or lack of it – of the latest incumbent. Something that should be hammered home during the next Built Environment Committee meeting.

There is a wealth of bumper material inside this issue. Check it all out for yourselves but I should point you towards our MEP coverage – this unsung aspect of the world of prefabrication offers essential services without which our built environment would simply grind to a halt.

Huge thanks to all our contributors, advertisers, and supporters for their help throughout the year, it is always genuinely appreciated – see you in 2024.

Gary Ramsay

Consultant Editor Email: gary.ramsay@offsitemagazine.co.uk

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To download your copy

CONTENTS

COVER STORIES

34 | Delivering MMC Frameworks

P06 | ACHIEVING NET ZERO

Dean Fazackerley, Head of Technical Procurement at LHC Procurement Group, explains what steps they have taken to better understand offsite manufacturers by using real-time factory assessments.

P46 | FRESH HORIZONS

SCHOOLS

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West Coventry Academy is the first of five pilot ‘net zero carbon in operation’ schools for the Department for Education and used the panelised Psi-FAST solution to deliver a hugely energy efficient, offsite manufactured design.

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British Offsite opened the doors to its new state-of-the-art Horizon factory recently, to show visitors first-hand, how they are bringing robotics and streamlined production processes to light gauge steel design.

42 | Platform for Change Digital tools, ‘kit of parts’ solutions and DfMA are central to the future of offsite manufacture. Charlotte Garrett, DfMA Lead at KOPE, told us some of the reasons why.

50 | Croydon High Life Tide, Vision and HTA Design have completed a landmark 937-home, multi-tenure development in Croydon and once again prove the value of offsite manufacture to the housing sector.

52 | WorkStack Completes with CLT

P70 | GRAITEC ROUNDTABLE

dRMM have completed Charlton WorkStack, a pioneering new model for high-density industrial space on compact sites and is primarily constructed from mass timber.

P79 | MEP FOCUS

54 | Mass Timber Lessons

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Graitec recently invited offsite sector experts to a roundtable discussion surrounding the links between design software tools and the environmental impact of the structures we create. Both interoperability and the circular economy were common themes.

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Mechanical, electrical and plumbing (MEP) services are all-important parts of the buildings where we live and work. We hear from several key businesses operating in the sector including Apex Modular Systems, NG Bailey, Pipekit, Uponor and Volumetric™.

NEWS

FEATURES

08 | Industry News

24 | Shining Lights Bringing together key businesses and industry leaders, the 2023 Offsite Awards rewarded the leading projects, people and products driving forward offsite manufacture and MMC technology – in case you missed it here is a recap of the evening’s big winners.

News and developments from across the UK offsite industry and wider construction arena including: The New Model Building offer a fresh ‘methodology’ for mass timber construction, the Housing Forum warns the UK’s planning system is not working well, VBC opens a facility in Ireland and Sheffield City Council receives energy efficient modular homes.

The Winner of Winners at the Offsite Awards 2023, the new £11.8million National Manufacturing Institute Scotland is winning many plaudits for its sustainable mass timber building.

62 | Putting Safety First The Light Steel Frame Association recently hosted an industry debate on the implications of important new safety legislation.

66 | In-House Expertise the Key Driving Force Frameclad’s Joint Managing Director Nik Teagle outlines why the firm’s in-house capabilities are part of the driving force behind their success.

76 | The New Sherriff in Town The Sherriff’s Gate development showcases why using precast concrete and MMC combine to provide project delivery with speed and precision.

TO THE DEDIC ATED T AND DEVELOPMEN OF APPLIC ATION SYSTEMS OFFSITE MEP NOV/DEC 2023 ISSUE ONE

HEAD TO PAGE 79 TO READ MORE

PLUG AND NS PLAY OPTIO STREAMLINING ILDING BU AL ITIC CR SERVICES

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AR SYSTEMS APEX MODUL r wiring and Providing modula emblies for mechanical sub-ass the offsite sector

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P84 NG BAILEY deliver a safer, Using MEP to future and greener better, faster

WWW.MEP

VOLUMETRIC™ sees the latest in ogy Kew Bridge Rise MEP pod technol bathroom and

.UK MAG AZIN E.CO

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COVER STORY INNOVARÉ OFFSITE

ACHIEVING NET ZERO SCHOOLS

West Coventry Academy (WCA) is the first of five pilot ‘net zero carbon in operation’ schools for the Department for Education (DfE) and used the panelised Psi-FAST solution to deliver a hugely energy efficient, offsite manufactured design.

2023 WINNER

1 WCA, which was procured through the DfE’s Modern Methods of Construction Framework (MMC1), is the result of a three-year research journey

by Innovaré Offsite and a major investment by its partner Bowmer + Kirkland (B+K).

It was the first of five pilot net zero carbon in operation schools for the Department for Education (DfE). At the initial planning stage, a webinar was held with all stakeholders hosted

by Headteacher Ana Neofitou with representatives from DfE, the community engagement team, and design and construction partners. The webinar was to share the vision for the school as well as offer assurances to the local community. Presentations included not only the designs for the academy but also the offsite construction process. Working with the academy, Innovaré used the rebuilding project as a learning tool, encouraging students to consider the many different career opportunities in construction.

Delivering 70% PMV Offering consistency from concept to completion the Innovaré team

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2 managed the structural design, manufactured the panelised solution, and rapidly installed the offsite manufactured system. Delivering a Pre-Manufactured Value (PMV) of 70%, Psi-FAST improves efficiencies by taking more construction processes offsite into a quality-controlled manufacturing environment. The factory fitting of vapour control, windows, and cladding enhanced the quality and integrity of important detailing whilst also accelerating the construction programme.

Innovare’s Psi-FAST panels included factory-installed windows, insulation, and brick-slip cladding with a Passive Purple Coating to substantially improve airtightness. The hybrid solution integrates Psi-FAST wall panels with roof cassettes and precast concrete floors and stairs.

Scope of works also included offsite manufactured volumetric plant rooms for the project which Innovaré designed and delivered in collaboration with M+E specialist, DBS. Increasing PMV to 70% was a key driver for the DfE, the Innovaré building solution achieves thermal

and airtightness levels required for net zero carbon in operation. Designed to address the performance requirements set out by the DfE Spec21 output specification for schools, Psi-FAST panels have been developed using market research and rigorous testing for higher-performance integrated systems delivering fire safety, thermal, and acoustic insulation with loadbearing capabilities.

With an A1-rated (non-combustible) board and insulation, class 0 surface spread of flame rating, and 60 minutes of standalone fire resistance, Psi-FAST technology has provided a safe and sustainable solution.

Through digital engineering combined with advanced manufacturing processes, Innovaré eliminated variability and risk, delivering predictable build times, cost efficiencies, and enhanced performance in line with DfE specifications and net zero carbon objectives. Not only highly sustainable, the Innovaré offsite approach is extremely cost-efficient. No scaffolding was required with less reliance

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COVER STORY INNOVARÉ OFFSITE

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on specialist trades. The Innovaré lightweight Psi-FAST system reduced foundation requirements, delivering cost savings and reducing embodied carbon. The project was delivered faster, and more safely, with installation tolerances and certainty only possible in a factory-controlled environment.

Net zero schools approach This project exemplifies the development Innovaré has undertaken to advance the application of the Innovaré offsite manufactured PsiFAST system. The use of the Psi-FAST system and material choices helped to deliver the DfE’s ambitious zerocarbon agenda. The result is a net zero carbon in operation building with high-performing acoustic attenuation combined with maximising natural light: ultimately providing an optimum learning experience for staff and students.

The former Education Secretary Nadhim Zahawi ‘broke ground’ at the start of construction to celebrate one of the first 100 schools to be developed under the School Rebuilding Programme. He said: “We are revolutionising the school estate to future-proof both our children’s education and the environment. With new school buildings that are net zero in operation, we are leading the way for more sustainable schools and supporting students and teachers to make a positive impact on the environment.”

Headteacher Ana Neofitou adds: “I’m delighted for the school and the school community. We have been working with the DfE for some time to get to the point we are at now. This investment will support us in driving forward our ambition for a better future for our young people.

5 The facilities and resources will undoubtedly improve the life chances of our school community as we work together to develop young people who are respectful, responsible, resilient, and ready to learn.”

A future model for education WCA is part of the Arthur Terry Learning Partnership (ATLP), CEO Richard Gill who is also Chair of the national Teaching Schools Hub Council said: “This is an academy with an exciting future, thanks to a huge rebuilding programme that equips it with first-class 21st Century facilities. Every child has the right to be a powerful learner, West Coventry Academy is committed to raising standards collectively through strong collaboration, teamwork, and mutual support.”

Innovaré Offsite demonstrated an innovative and collaborative approach to supporting the design and construction process, integrating its Psi-FAST hybrid structure to meet the brief for a modern, welcoming, energy-efficient school with a highquality architectural design reflecting its collective aims and ethos. As the academy is located a short distance from the Innovaré factory, many of the team have children at the school.

As part of Innovaré’s commitment to increase social value and community engagement, they have also hosted visits from WCA students and staff.

Gareth Ellison, Director at Innovaré, said: “Our team has worked closely with our partner, Bowmer + Kirkland, to make the benefits of the Innovaré psi-FAST offsite system a reality at West Coventry Academy, providing a great learning environment and experience for students and staff.

We’re very proud of what the wider team has achieved to help deliver the DfE vision of a net carbon zero school estate.”

The £38.4million transformation of WCA is leading the charge for more sustainable schools and helping students and teachers to make a positive impact on the environment.

Supporting the DfE’s ambitious zerocarbon agenda – the use of Innovare’s Psi-FAST system has reduced energy requirements for the lifetime of the academy. With advanced offsite technology, the new academy opened in September 2023, on schedule and budget, providing a high-quality environment for 1,500 students.

For more information visit: www.innovareoffsite.co.uk Images: 01-05. West Coventry Academy is a leading example of net zero, energy efficient offsite design and delivery. Courtesy Bowmer + Kirkland/@bandkphoto

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UK INDUSTRY NEWS VBC Opens Irish Global Centre of MMC Excellence

MMC CONFERENCE 2024 Dates confirmed as 22 & 23 May Full details at www.radarbookingsystem.co.uk/mmc-ireland-national-conference-2024

The expansion of global modular building specialist, Volumetric Building Companies (VBC), continues with the opening of its first operation in Ireland. This new facility is set to become an international centre of excellence for MMC to serve Irish, UK, European and global markets.

VBC has appointed a team of 27 product designers, architectural technicians, and support staff who, based at its new facility in County Monaghan in Ireland, bring vast, world-class experience in timber panelised solutions. This move is expanding VBC’s already diverse modular product portfolio into timber panelised construction and will increase its design and engineering capabilities globally.

VBC CEO Vaughan Buckley (pictured) explains: “Our new Irish team members, based in Monaghan, surrounded by world class companies and having been originally brought together through the vision and leadership of Gerry McCaughey, represent a bright future for both VBC and the wider offsite construction sector.

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“Their vast experience in a variety of modelling and design technologies will allow us to integrate the team quickly whilst continuing to innovate at an even faster pace. Ireland and its healthcare, housing and infrastructure needs represent a huge opportunity for partnership and collaboration with the offsite sector and VBC’s investment in Ireland is a clear signal of our desire to strengthen that partnership.”

Andy Smith, UK Director at VBC added: “This new facility is a foundation for our launch into new market sectors, locally and globally. We are already seeing significant opportunities in Ireland, particularly in healthcare, which are creating increased demand for our steel-framed modular solutions. As a location, Ireland has excellent links with the UK and Europe.

The move into Ireland also demonstrates VBC’s ongoing confidence in the offsite sector and its financial stability as it continues to expand and innovate.”

Sara Ann Logan, Vice President of Design at VBC also added: “We are absolutely delighted that this team

has joined VBC. We are a design-led and technologydriven business and the valuable skillsets that this design and product engineering team are bringing to our global business are hugely important. This is a really strong team of designers, engineers and architectural technicians who have worked together for many years and who can now help us to create a global centre of excellence for production engineering for industrialising construction. Their expertise will also support our timber-framed volumetric and steelframed modular businesses.”

VBC’s plans will include a series of show suites at the new Monaghan facility for its steel-framed modular and panelised solutions for the Irish, UK and European markets. Led by CEO and founder Vaughan Buckley and headquartered in Philadelphia, VBC is one of the world’s largest modular businesses. It offers advanced steel-framed modular and innovative timber construction technologies. VBC has three offsite manufacturing centres – Tracy in California, Berwick in Pennsylvania and Chojnice in Poland.

Source: www.vbc.co

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UK INDUSTRY NEWS Byldis Under Fresh Ownership Private equity investor Mutares SE & Co. KGaA has announced the successful acquisition of MMC provider Byldis. This strategic takeover marks a significant milestone in Mutares’ commitment to innovation and growth in the construction industry.

Byldis has established itself as a market leader in precast concrete and facade technology in the UK and offers a range of innovative offsite solutions. This acquisition not only solidifies Mutares' presence in the UK and European markets but also enhances its portfolio with Byldis' expertise and capabilities.

The integration of Byldis into the Mutares family reflects a shared commitment to driving excellence and delivering sustainable solutions in construction.

With this acquisition, Mutares is poised to offer even more comprehensive and sustainable construction solutions to clients and partners across the UK and Europe.

Michael Koch, CRO/Interim-CEO of Byldis, expressed excitement about the acquisition, saying: "Byldis is a remarkable company with a proven track record

of innovation and excellence. This acquisition is a strategic move that enhances our capabilities and cements our commitment to delivering cutting-edge solutions to our clients. We are thrilled about the potential this partnership holds. Key benefits of the move will see enhanced innovation by: “Continuing to push the boundaries of modern construction methods, delivering state-of-the-art solutions to meet the evolving needs of our clients.”

Henk Berendsen, Financial Director of Byldis added: "Joining forces with Mutares is a thrilling prospect.

Their commitment to innovation and sustainable practices perfectly aligns with our own values.

Together, we are poised to make an even greater impact on the construction industry and drive positive change."

The acquisition of Byldis by Mutares is a powerful combination of two industry leaders, destined to redefine the landscape of modern construction methods. This collaboration is a testament to the shared vision of both companies, and the bright future they are building together.

L-R Michael Koch, CRO/Interim-CEO Byldis and Henk Berendsen, Financial Director Byldis Source: www.byldis.com

Vandersanden Helping Create New London Homes One of the first residential developments created and offered for sale by Westminster City Council – Cosway Street, Marylebone – is a collection of 49 contemporary homes set around an attractive communal garden. Vandersanden’s Cayenne, Woodland Mixture and Lima bricks are integral both to the precast Design for Manufacture and Assembly (DfMA) panels, forming the facades, and the traditional hand-laid brickwork lining the balcony spaces.

This landmark building was inspired by the area’s Georgian terraces and Victorian mansion blocks.

From the choice of materials to the precise proportions and the gentle curves of the scalloped panels, every element of the architecture has been considered to help stitch the scheme into its setting.

The design for Cosway Street was by Bell Phillips, realised by Osborne and their delivery architects David Miller Architects.

David Miller Architects took over the project post planning approval. The design intent was to craft the building as if it had been carved from brick. A key decision was to employ prefabricated DfMA brick panels for the main facades, alongside traditional hand-laid brickwork for the inset balconies. Using this approach allowed the construction team to build

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quickly to a precise, high quality and efficient standard in a controlled manufacturing environment, using less energy and carbon and creating less waste.

The idea was to split the building’s mass using the materiality, colours and textures of the three different bricks and the scalloped form of the panels to respond directly to the context of the site. The choice of bricks was incredibly important and had to meet the planning design intent explains Sundas Rohilla, project architect at David Miller Architects. “We’d used Vandersanden products on a previous project for Westminster City Council and we’re now using them to deliver two other projects in the same area, Ashbridge Street and Ashmill Street. It comes down to the hues and the textures that the bricks offer and the company’s commitment to sustainability.”

The mass of the building is reduced not only by the different blocks of brick colours but also by the gradation of the mortar colours across the façade. In all, there are five mortars with the darkest at the base

of the wall and the lightest at the top. Using mortars in this way meant that there was no need to use different brick types to achieve the same effect, but it did mean that it was essential to have bricks of the right texture and consistency. The brick panels were pointed offsite in the factory.

With such a complicated design, offsite construction meant that precise tolerances could be achieved, and the quality of the brickwork could be seamless.

In all, 285 precast panels were manufactured by Decomo in Belgium to create 3.500m2 of finished facades. Dueto the façade’s differing curvatures, Decomo had to cut and bond the bricks to various sizes with 117 different shapes for each of the three brick colours. The bricks used by Decomo in Belgium exactly matched those being used on-site by the bricklayers, with Vandersanden working closely with the design team and directly with Decomo to manage this process.

Source: www.vandersanden.com

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UK INDUSTRY NEWS Homes Facelift for Sheffield City Council

Sheffield’s first ‘net zero in operation’ council homes were recently safely lifted into position at the Duffield Place site in Woodseats. Before being transported to site, the homes were built in a quality-controlled UK factory using volumetric modular construction.

Sheffield City Council is working with ZED PODS Ltd to deliver six self-contained single person, high-quality homes.

The homes were designed by ZED PODS team of in-house architects, using a ‘fabric-first’ approach – with walls, ceilings, windows, doors and roofs all super-insulated, achieving high levels of air tightness.

The homes are all electric, fitted with heat pumps and rooftop mounted solar photovoltaic panels. This ensures that 100% of the in-use carbon emissions are offset, making the homes ‘Net Zero Operational Carbon’. This significantly reduces running costs for residents and contributes to the council’s ambition to reduce its carbon emissions to net zero by 2030.

In addition, a whole life cycle carbon assessment is being undertaken to identify all environmental impacts of the scheme over its lifetime.

These homes are being delivered as part of the council’s Stock Increase Programme, with investment

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from both the council (including from the Local Renewable Energy Fund) and the Department of Levelling Up, Housing and Communities.

This project also delivers another first for the city – the Council’s first dedicated move-on homes. The homes will be managed by the Council, providing access to both an affordable home and individual support for people who have previously experienced homelessness. This support will help people to successfully move to a permanent home within two to three years. As part of Changing Futures Sheffield, the Council has received valued input from people with lived experience of housing support services to develop this project.

Chair of Sheffield City Council’s Housing Committee Councillor Douglas Johnson said: “I am delighted to see the council deliver its first 'net zero in operation' council homes – this is an important step for the city as we continue to find ways to address the net zero challenge and reduce the impact of the cost-of-living crisis on our residents. I look forward to visiting the new homes, and I will be particularly keen to talk to residents about their experience of living in these homes. It’s also great to see this project deliver much

needed supported housing on a council-owned brownfield site, whilst at the same time retaining and enhancing the adjacent green space through the planting of new trees”.

Tom Northway, Chairman at ZED PODS Ltd said: “These houses will be of the very best design in terms of environmental performance and internal specifications, providing ultra-low energy bills for residents. Our inhouse team have worked closely with the client in every stages – from concept design to planning, from offsite fabrication of modules to training their maintenance team before the modules were brought to the site. This will be ZEDPODS’ first project in the City and is a brilliant example of how working with the local community, council officers and supply chain partners we can unlock constrained sites and deliver much needed affordable homes.”

The on-site works started in March 2023 at the same time the homes were being manufactured offsite. The new homes are expected to be completed during Winter 2023/24.

Source: www.zedpods.com

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UK INDUSTRY NEWS TDUK Publishes Library of Timber Knowledge Sheets Timber Development UK (TDUK) has published the first set of its huge new library of Timber Knowledge Sheets – with 50+ now available for download.

The new knowledge sheets introduce and answer common questions about every aspect of working with wood, from the difference between hardwood and softwood, through to acoustic regulations, Eurocode 5 principles, embodied carbon, and sourcing timber sustainably.

Developed with experts from Edinburgh Napier University, and TDUK’s unrivalled membership network of supply, manufacture and design professionals, these 50+ knowledge sheets are the first batch of a planned 140 to help support the industry to build better with wood.

TDUK chief executive, David Hopkins says: “Following the merger between the Timber Trade Federation and TRADA last year, we promised to connect the timber supply chain, lead best practice, and accelerate a low-carbon future. Our Timber Knowledge Sheets are another example of us doing exactly that – and represent a big step towards our vision of the UK as a country where timber is the number one material choice for all construction projects.

“Amidst a climate emergency, changing how we build is crucial – as it represents a major portion of our

carbon footprint. The material and design choices we make today will shape the future we have tomorrow.

Timber is an existing, proven solution to how we construct a low-carbon future, with independent studies showing that methods such as timber frame have up to 20% lower embodied carbon than traditional masonry.

“Fundamentally, trees absorb carbon, and when turned into long term construction products, can store it for decades if not millennia. Most other materials you find on building sites do the exact opposite – spewing tonnes of carbon into the atmosphere.

Taking on climate change requires collective action, so a big part of TDUK’s mission is to make sure that everyone in the timber supply chain has the opportunity, the tools, and the knowledge to succeed.

These sheets, released today, add considerable depth to our online library, which is already the largest, most

comprehensive source of timber knowledge in the UK. This will support all to build better with wood.”

The Knowledge Sheets touch on all topics timber and are aimed at architects, engineers, designers, builders, installers, contractors and merchants. Between pages, you will find introductions to all kinds of timber components and methods of timber construction – all described in an accessible and easy to understand fashion. The Knowledge Sheets also contain plenty of regulatory guidance, 'best practice' information for working on site, as well as practical introductions to working with timber in challenging contexts such as flood-prone areas. These Timber Knowledge Sheets follow hot on the heels of the recently published Span Tables for C16 and C24 timber. A further 90 Timber Knowledge Sheets are to be published imminently.

Source: www.timberdevelopment.uk

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THE POWER OF FASTENING

UK INDUSTRY NEWS New Methodology for Mass Timber Construction Available

Thistleton Architects, cost consultants Gardiner & Theobald and fire engineers at UCL (University College London), has been developed to help unlock and stimulate the construction of net zero homes.

The New Model Building project team have been working with NHBC, who have reviewed the New Model Building methodology. Chris Hall, Technical Innovation Manager at NHBC said: “We support the use of natural construction materials in housebuilding when employed in line with our technical standards.

Natural construction materials can offer various advantages during the construction process and are being increasingly employed across the industry.

Timber is very versatile and perhaps the oldest of all construction materials, and its use in housebuilding continues to evolve.”

The New Model Building is exemplar guidance for building residential developments in a climate emergency, illustrating how substitution of a traditionally constructed superstructure with engineered timber can reduce the whole life carbon footprint by over 50%.

An expert cross-industry team of engineers and architects has launched a pioneering set of design principles, demonstrating how mass timber can be used safely to construct multi-storey residential buildings, in full compliance with UK building regulations.

The development of ‘The New Model Building’ was funded in part by Built by Nature, a network and grant-making fund dedicated to accelerating the timber building transformation in Europe and the UK. The new methodology was created by structural and sustainability engineers at Buro Happold, Waugh

Building Product Design Appoints New MD

Jonathan Roynon, Technical Director at Buro Happold, said: “This groundbreaking design and engineering work demonstrates just what’s possible with mass timber. Embracing the use of the material in medium rise residential buildings and beyond will be a critical part of our response to the climate emergency. With the team’s breadth of experience with mass timber, we’ve been able to develop a comprehensive methodology for delivering all parts of a project, including architectural designs, the structure, buildability plans and fire safety.

“The key element of our engineering work – the structural strategy – is flexible too, so it can be adopted by as many construction projects as possible. And we’ve made sure the strategy gives absolute clarity on how to build a structure that’s safe.

Ultimately, we hope all this work will encourage the construction industry to reemploy timber as a core construction material, in our drive to achieve net zero.”

The methodology has been pre-assessed by the NHBC to ensure that it meets its technical and safety standards. This facilitates developers to more easily apply for Buildmark for buildings, NHBC’s ten-year warranty and insurance cover for newbuild homes.

In the wake of the Grenfell tragedy, changes in UK building regulations prohibiting the use of potentially dangerous external cladding systems in residential buildings has created hesitancy around the use of engineered timber in construction. This lack of confidence threatens the UK’s ability to meet emerging embodied carbon targets and address the climate change crisis, despite wide acceptance of the knowledge that the use of structural timber is one

Paul King, CEO of Built by Nature, added: “Gamechanger is an over-used phrase, but truly applicable here. Six storey residential timber buildings that exceed UK Building Regulations, meet GLA policy and slash embodied carbon by over 50% – all preassessed by a major national warranty provider. We believe this will unlock a significant shift in the way we build housing in the UK.”

Building Product Design has promoted Ben Gerry to the role of managing director following his successful tenure leading the company’s commercial operations.

With over 15 years manufacturing and construction industry experience, Ben joined Building Product Design in November 2020 as commercial director.

He has gone on to play a key role in the development of the company’s subsidiary brands which include Glidevale Protect, Passivent and Kingfisher Louvres as well as Building Product Design’s bespoke manufacturing solutions.

subsidiary brands. Key to this has been the creation of a dedicated Group Sustainability Board which, in his new role, Ben will be instrumental in developing further. Current initiatives include the creation of Environmental Product Declarations (EPDs) for key products and a focus on achieving accreditation to the ISO 50001 energy management standard across both of Building Product Design’s UK based manufacturing facilities.

In his new role of managing director, Ben will also draw upon his earlier experiences of working both in and outside of the construction industry, including his leadership of SMEs and service focused businesses, to further strengthen Building Product Design’s product portfolio and customer service proposition.

Building Product Design is one of the UK’s longstanding leading forces in the development of building ventilation solutions and specialist building products. The company’s commitment to building healthy solutions is supported by its ongoing investment in reducing the environmental impact of its products and manufacturing operations across its 14

of the primary ways to reduce the carbon emissions produced by construction.

As part of The New Model Building launch, its design principles and details have been published and made available at: https://builtbn.org/solutions/new-modelbuilding/54

Commenting on his promotion, Ben Gerry said: “I am excited to lead Building Product Design and our fantastic brands forwards. After spending nearly three years as commercial director, I know that the passionate people here and the expertise they bring are a real asset to the company’s ongoing success and I am looking forward to continuing to work with our talented teams to build on this strong foundation.

As well as supporting the subsidiary businesses under the Building Product Design brand, I will also be working closely with our parent company Wienerberger to bring a wider range of building materials solutions to the market.”

Source: www.glidevaleprotect.com

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

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UK INDUSTRY NEWS Hill Group Donates Eight Solohaus in Bristol

The Hill Group has gifted eight SoloHaus homes to Places for People Living Plus to help tackle homelessness in Bristol. Designed to provide followon temporary accommodation for people who have experienced homelessness, the purpose-built modular homes were handed over to Places for People in September. Senior staff from Hill, Places for People, and Bristol City Council came together to celebrate this milestone at Derby Street, Bristol.

Andy Hill OBE, Group Chief Executive at The Hill Group, comments: "We're excited to donate eight SoloHaus homes to Places for People Living Plus, bolstering its efforts to tackle homelessness. These homes will make a tangible difference to residents’ lives by providing secure, modern, and comfortable accommodation. We're confident they'll help many more people get back on their feet and regain the dignity they deserve."

The SoloHaus homes provide a safe, comfortable, and independent space for residents and arrive fully furnished, ready for installation onto a pre-prepared site. Designed to house single people, the homes have a 60-year lifespan and are built to Future Homes Standards, exceeding building regulations for energy efficiency and sound insulation.

The SoloHaus homes will be managed by Places for People Living Plus, the UK’s leading social enterprise.

The organisation provides vital advice and support across Bristol to people who are struggling with housing; this includes help with benefits, financial hardship, funding and grants, and local welfare support.

The land on which these homes are situated has been transferred to Places for People by Bristol City Council for nominal rent on a 60-year lease, ensuring longevity and stability for the scheme.

The council has also secured a significant funding contribution from the Department for Levelling Up, Housing, and Communities (DLUHC) Rough Sleeping Accommodation Programme that will cover the salary of a support worker at the development for 18 months.

James Brown, Transition and Implementation Lead, Places for People, added: "Having safe independent accommodation is a vital part of transitioning back to a more stable living arrangement for those who have experienced homelessness. I would like to thank Hill for providing these impressive modular homes which will enable us to give support and guidance to even more people, helping them to develop the skills, confidence, and resilience to take the next step into independent living. I would also like to thank Bristol

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City Council, who has been pivotal in making this scheme a reality by securing the land to Places for People for a minimum term of 60 years.

Councillor Tom Renhard, Cabinet Member for Housing Delivery and Homes at Bristol City Council: added “This is a brilliant project that will transform the lives of Bristol residents who need some extra support to get them back on track and working towards independent living. In 2021/22, Bristol built 2,563 new homes, exceeding the mayor’s ambitious manifesto target.

More is needed, however, if we're to tackle a housing crisis that sees over 20,000 households on our housing waiting list. We're taking ambitious strides to explore a range of innovative solutions, and this project allows us to make the best use of the space we have in the city.” Produced in the West Midlands

by Hill’s manufacturing partner Volumetric Modular, over 80 SoloHaus homes have now been donated to organisations around the UK as part of the Foundation 200 project.

Source: www.hill.co.uk www.volumetric.co.uk

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

UK INDUSTRY NEWS NMITE & BE-ST to Create National Asset for Built Environment Professionals New Model Institute for Technology and Engineering (NMITE) has signed a formal agreement with Built Environment – Smarter Transformation (BE-ST) to catalyse a nationwide network of advanced engineering, manufacturing, and learning hubs.

The strategic partnership will enable best-inpractice knowledge and understanding to be shared and tailored by region based on the UK’s varied archetypes, typologies and capabilities. BE-ST and NMITE see the collaboration as the start of creating a broader network of collaborating partners who can create impact at scale. This is exemplified by the existing partnerships with Timber Development UK and Edinburgh Napier University, with more regional partnerships to follow.

The approach will provide a framework for collaboration, with the goal of creating greater connectivity between these local ecosystems to deliver sustainable built environment training on a national scale.

Through this partnership, NMITE will be able to leverage BE-ST's vast experience of delivering skills development training and learn from its approach to establish a model on a national scale, while BE-ST will benefit from growing its network in the South of England.

Although the formal agreement between the organisations is new, NMITE and BE-ST have been working together for some time. BE-ST has been involved in projects such as NMITE’s Centre for Advanced Timber Technology (CATT), which now plays a strategically influential role in supporting and expanding the use of timber in modern construction.

The new strategic partnership will enable both new and ongoing work between the two organisations by providing greater staff mobility and knowledge sharing, particularly in relation to net zero.

Their shared ambitions to accelerate the built environment’s transition to zero carbon, support the development of world-leading built environment professionals, increase the adoption of renewable natural resources to deliver a more sustainable and resilient built environment, and create a more diverse and inclusive construction industry for built environment professionals to flourish and excel, also sit at the heart of the partnership.

Sam Hart, Head of Modern Methods of Construction at BE-ST said: “BE-ST and NMITE have a proven

track record of working together to deliver impactful projects. Through this formalised partnership, we have a real opportunity to create a scalable model of regional learning hubs – a kind of basecamp for training in England - that we would like to see become a national asset.”

Robert Hairstans, Director of CATT at NMITE added: "I’m excited to see that the partnership between BE-ST and NMITE now has the framework behind it to grow and sustain. Together, I am confident we can advance the development of problem-solving skills, innovative thinking, and career development opportunities through the establishment of collaborative regional hubs, capable of sharing best practice and tailoring it to the specifics of their regional contexts. In turn, this will support the accelerated decarbonisation of the built environment and the development of services, which would not be achievable if we were working in isolation.”

Source: www.nmite.ac.uk www.be-st.build

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UK INDUSTRY NEWS BBA & Bureau Veritas Partner for Product Marks The British Board of Agrément (BBA) is collaborating with Bureau Veritas (BV), a world leader in testing, inspection, and certification, to deliver dual CE and UKCA marking to manufacturers of construction products according to EU and UKCA Construction Products Regulations.

“At the BBA we are committed to removing complexity for our clients: such as the changes postBrexit and the transition to UKCA Marking. We believe in helping our clients get the results they need, as quickly as possible,” commented Jason Harries, New Product Development Lead, BBA. “This collaboration with Bureau Veritas, means that we can support our clients who have manufacturing facilities in a number of European countries. Through working together, we help our clients save time and cost that often accrue as a result of additional inspection. With the added benefit of reducing our carbon footprints through avoiding unnecessary travel.”

BBA is designated as an approved body by the UK Government for construction products regulation in the UK. BV is a notified body for the purposes of the EU’s Construction Products Regulation (No. 3052011) in 11 countries: Italy, Spain, Portugal, Slovenia, Turkey, Latvia, Greece, the Netherlands, Finland, Austria and Denmark. Thanks to their partnership, manufacturers of construction products will be able to benefit from dual CE and UKCA markings.

Karine Kutrowski, Industrial Product Certification Vice President, Bureau Veritas, commented: “We’re pleased to collaborate with the British Board of

Knauf Launches New Sustainability Report Knauf has announced the release of their 2022 Sustainability Report. The report outlines Knauf’s goals of achieving Net Zero by 2045 and the roadmap to achieve this.

The report discusses three focus areas for achieving these goals: People, Planet and Prosperity. Within each of these pillars, there are specific actions Knauf is taking to achieving these goals.

Measurability and accountability are key in setting these sustainability targets. The partnership with Planet Mark, an independent business which certifies company’s sustainability progress through reviewing carbon emissions and Environmental, Social, and Government (ESG) criteria, is central to this.

Ian Stokes, Knauf UK & Ireland Managing Director, introduces the report and sets out what it means

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Agrément (BBA) to provide services for certification and surveillance of Factory Production Control (FPC) for the manufacture of construction products. This partnership will offer our clients more support in achieving dual regulatory compliance and access to both the EU and UK markets.”

BBA is also pleased to welcome Julie Bregulla as its new Chief Technical Officer (CTO), who took over from Professor Bill Hewlett in November. Julie will join the Senior Leadership Team and will be overseeing the Quality and Assurance Teams, supporting the BBA in driving industry safety and quality by providing services that help clients by enabling innovation, identifying risk and demonstrating fitness-for-purpose.

Julie spent 17 years of her career with the Building Research Establishment (BRE) before taking up a Director and Professor role at The Engineering and Design Institute (TEDI)-London. TEDI is a higher education start-up for future engineers, jointly founded by Arizona State University, King's College London and UNSW Sydney. Julie has worked in academia, consulting and construction, giving her a

blended experience in the multi-faceted interactions of engineering practice. Julie is a Chartered Civil Engineer, a Fellow of the Royal Academy of Engineering, Fellow of the Institution of Civil Engineers and a Member of the Expert Witness Institute.

She holds a PhD in structural fire engineering and has extensive experience in the research and development, standards and certification of both innovative and established products in the built environment.

Julie said: “It’s an exciting time to be joining the BBA, an organisation that has been at the forefront of shaping the construction industry landscape for decades. I’m looking forward to working alongside the dedicated team here to support industry and stakeholders, driving forward safety standards and their implementation.”

L-R Julie Bregulla and Jason Harries Source: www.bbacerts.co.uk www.bureauveritas.com

to the business for both internal and external stakeholders saying: “Sustainability is not a nice to have, but an essential part of the way we live and work. We will put people and communities first, achieve net zero carbon and be a key player in the circular economy.

“Our strategy focuses on three core areas where we will bring real action and measurability to ensure progression. We’re educating and encouraging all our staff, suppliers, and stakeholders to take on more sustainable practices to help meet these goals.

This report is our marker in the ground and offers a focused route to achieving net zero.”

Through this partnership, Knauf can effectively measure and verify progress not just in carbon reduction, but social value too. This extra layer adds value to the measures the business is taking and demonstrates the commitment to meeting the net zero target. In measuring progression to date, Knauf carbon emissions are down 8.2% in 2022 compared to the 2021 baseline. Within that reduction, Scope 1 and 2 emissions have been reduced by 7.9%.

Social value has also improved year-on-year, with a 64% increase underlining the positive impact Knauf continues to have on employees and local communities.

To read the report in full, including details of the actions taken and results to date, visit knauf.co.uk/about-us/sustainability

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

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UK INDUSTRY NEWS Combilift Celebrate 25 Years in Materials Handling Combilift recently celebrated 25 years in business with a huge customer and media event at its Monaghan headquarters that included three new product launches. This included the new Combi-AGT Autonomous Guided Forklift Truck. The autonomous truck solutions combine sophisticated innovative technology to provide the highest levels of productivity and safety. The Combi-AGT can operate autonomously in guided aisles and free-roaming while also featuring a manual driving option.

Also unveiled was Combi-Connect, a telematic software product that provides customers with greater levels of insight into fleet management and usage, providing real-time data on fleet performance, including location tracking, usage analytics, and maintenance alerts. With this invaluable information at their fingertips, businesses can improve and enhance operational performance.

Speaking at the event, Minister for Rural and Community Development, Heather Humphreys TD said: “Over the past 25 years, Combilift has made a very important impact to the Irish economy.

Combilift is a visionary company in every sense, and I’m delighted that the Irish government, through Enterprise Ireland, has supported Combilift through its incredible 25-year journey.”

Housing Forum Warning Over UK’s Planning System A new report released by the cross-sector housing body The Housing Forum, sets out a roadmap for how the planning system can be improved. The report notes that the planning system “is not currently working as well as it should be” and presents solutions to the planning crisis in three areas:

• Building support for new housing and harnessing the benefits of planning • Reducing burdens and improving efficiency, and • Addressing staff shortages and improving skills.

The past year has seen a crisis in housebuilding.

England is “the most difficult place to find a home in the developed world” and the 232,820 homes built last year is far off the government’s target of 300,000. The planning system is one of the main contributing factors preventing more ambitious housebuilding, and planning reform is rising up the political agenda, with Keir Starmer pledging to ‘bulldoze’ through it and Rishi Sunak attempting to reform nutrient neutrality rules in the planning system to get more homes built.

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Martin McVicar, Managing Director of Combilift added: “We have a track record of innovation at Combilift.

We invest 7% of our revenue annually in R&D and today is the culmination of many years’ hard work.

We are delighted to be continuing this tradition of innovation 25 years on. Now employing over 800

people in Monaghan and 200 people in other locations across the world, the success of Combilift is testament to our people, our customers and our supporting dealers around the world. We are looking forward to the next 25 years at Combilift.”

Source: www.combilift.com

In Building support for new housing and harnessing the benefits of planning’, the report suggests creating a statutory role for the Chief Planning Officer in local authorities, embedding planners in other teams across a local authority, and integrating the role of planning within a local authority. Planners should be empowered to advocate the benefits of new housing both in terms of meeting housing need and supporting economic development of their local area.

In Reducing burdens and improving efficiency, the report lays out reforms which can be taken to the planning system to streamline it, including removing nutrient neutrality from the planning system and ensuring that developers for larger applications are provided “good and insightful” pre-planning advice.

In Addressing staff shortages and improving skills the report highlights the issues with recruiting and retaining planners in local authorities and promotes the importance of a dedicated case officer to each planning application and matching local authority planners’ salaries to their private sector counterparts.

It also calls on the government to improve routes into planning and encourage former (retired) senior planners to support local planning authorities dealing with householder applications.

Shelagh Grant, Chief Executive of The Housing Forum, said: “We know from our membership in The Housing Forum that there are many talented and

passionate planners working in local authorities and in the wider housing sector who share our ambition and want to see the benefits of new housing for their local areas. The planning system, however, is not currently working as well as it should be, and we hope that the ideas set out here offer some possible ways forward.”

Source: www.housingforum.org.uk

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

UK INDUSTRY NEWS £2.4M Bathroom Pod Contract for Greystar Student Scheme Offsite Solutions has announced its latest contract win in the student living sector – a £2.4million project to manufacture 761 GRP shower pods for McAleer & Rushe for a new 20-storey development at Wembley Park developed by Greystar. This is Offsite Solutions’ second contract for McAleer & Rushe and will involve the production of standard and larger accessible and adaptable floorless enhanced GRP bathroom pods.

Designed by HTA Design, the 770-bed scheme will be operated under the Canvas brand and will open to its first occupants in September 2025. Commenting on the use of pods, Harrison Hart, Development Associate at Greystar, said: “As a business, we are driving the use of offsite construction for bathrooms for the majority of our student schemes as it aligns with our ESG commitments. Pods generate less waste through more efficient use of materials, less traffic to site, provide a better working environment for the bathroom fitout, and quality is better with significantly reduced snagging at practical completion.

“Design development for the bathrooms on this project has been an incredibly quick process and has been completed at an earlier stage than if we were using in-situ bathroom construction. It is then possible to see the first off pod early on to verify and refine the design detailing, and to inform the design of

the student bedrooms. It also provides a benchmark for quality control. Having one single supplier is very helpful to simplify procurement, design and site management, and still gives us flexibility.”

Darragh Greenan, Contracts Director at McAleer & Rushe added: “The use of bathroom pods for this project reflects our commitment to supporting offsite manufacturing and all the benefits it can bring – increasing efficiency on site, reducing material deliveries and the associated carbon emissions, and reducing site waste. There are also clear quality control advantages as we have the opportunity to assess the quality of the bathroom finishes before going into full production.”

Sustainably manufactured and fitted out offsite in controlled factory conditions, the finished bathrooms

for Wembley Park will be installed on-site in just a few hours. Each pod will be fully fitted out at Offsite Solutions’ factory in Somerset with a wall hung toilet, D-shaped wall hung basin, a vanity shelf with solid surface worktop, circular mirror above the basin, a mirrored two-door cabinet, a shower with a riser rail and a bi-fold shower door.

All the pods will be supplied floorless – a highly efficient solution to minimise floor build-up for highrise residential projects. The accessible pods will be Part M compliant and will have dropdown and fixed grabrails, a low-level basin positioned closer to the toilet and a lever tap. These bathrooms will have a large-format tile-effect finish Source: www.offsitesolutions.com/ floorlessGRP

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UK INDUSTRY NEWS King’s Lynn Hospital Combines Offsite and Collaborative Working

The £12.5million endoscopy unit built by MTX at the Queen Elizabeth Hospital King’s Lynn NHS Foundation Trust (QEH) is being recognised as an outstanding example of combining offsite design and advanced construction techniques with collaborative working.

The project employed multi-level BIM tools and Construction Playbook methodologies to deliver a high-quality facility to time and budget, achieving 72% pre-manufactured value, 49% increased patient throughput and an excellent satisfaction score from the QEH. Offsite technology was a major element in delivery of the final project which opened in September 2022 – delivering cost-predictability, economy, accuracy, speed of installation, and reduced energy consumption and building running costs. Construction of the new unit also incorporated ground-breaking carbon and energy efficiency reduction plans contributing to the Trust’s net zero policy targets, with the collaborative early contractor involvement (ECI) relationship and the use of digital technology and simulations resulting in savings for the whole life of the facility.

The new endoscopy unit uses digital design innovation and technology to improve the patient care and experience. Bespoke interactive endoscopy information screens, smart touch screens in nurse bay areas, smart room sensors capturing information such as light and temperature levels that impact patient experience, and a ‘live rooms’ signage and booking system are among the innovations.

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The Trust identified the need for a new two-storey, 2,600sq. m. development to modernise obsolete facilities and enable endoscope procedures to take place in one facility to meet acute clinical demand.

On behalf of QEH, exi Group contracted MTX to develop the new endoscopy unit using a BIM and ECI approach through the NHS SBS Modular Building Framework quality selection - embedding the Trust’s carbon-led net-zero goals. Initially MTX was appointed on a pre-construction service agreement to work closely with the Trust’s clinical and technical teams to develop the design from conception.

The project delivered against its goals achieving an accelerated return on investment by 14 months, 41% less CO2 compared to a traditional construction solution, an MMC platform approach that achieved 72% PMV, 26% reduction in carbon emissions for the concrete floors when compared to previous installations at the Trust, zero defects and zero accidents.

Offsite technology was a major element in the delivery of the final project – offering cost-predictability, economy, accuracy, speed of installation, and reduced energy consumption and building running costs. Units digitally designed and optimised in the factory reduced risk whilst delivering advanced pre-assembled factory standards and high levels of quality assurance. Cost predictability was a key factor in pre-construction with Revit modelling allowing

accurate RIBA stage 4 costing, and clash detection design workshops reducing on-site conflict.

Cost saving achieved included a 15% MMC saving vs traditional building, a 65% reduction in on-site labour and utilisation of local SME resources for assembly and completion, under MTX management.

Initiatives to increase the speed of delivery included weekend working, extended factory hours that achieved the manufacture of ten modules per day during winter, the use of recycled Legato blocks to accelerate groundworks and save carbon and direct radio communication between the construction team and the A&E Dept that optimised crane usage to mitigate delays without disrupting blue-light movements.

QEH Trust Project Manager Tracey Scoot, from exi Group, explains: “This was the Trust’s first true collaborative early contractor involvement (ECI) project. The approach to offsite construction was followed on this project due to extremely restricted timescales within both the Trust and healthcare arena.

Modular construction allowed for a higher quality build due to the standardisation of offsite methods and provided cost certainty through efficiencies in both design, resource, and labour required on site. The project showcases the benefits that collaborating with specialist supply chain can bring to such a scheme.”

Source: www.mtxcontracts.co.uk

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

UK INDUSTRY NEWS NHBC Brings Back ‘Building for Tomorrow’ NHBC, the UK’s largest new homes warranty and insurance provider, is pleased to announce the 2024 return of its flagship event series Building for Tomorrow. Taking a pragmatic approach to making progress, finding solutions and creating connections in the house-building industry, Building for Tomorrow offers future-focused professionals from across the sector the chance to network and learn about the latest developments in British house building.

Delegates will have the chance to hear from leading organisations including the Future Homes Hub and BEAMA, manufacturers of the latest technology, Modern Methods of Construction (MMC) experts and NHBC’s own Standards and Technical teams. As a rolling programme of events around the UK, Building for Tomorrow will visit eight major cities during February and March 2024.

NHBC’s purpose has always been to help raise standards in house building by championing high-quality homes both now and in the future. The Building for Tomorrow 2024 events reaffirms the housebuilding industry’s continued commitment to build quality and highlight the key role this plays in supporting continuous improvement. An impressive roster of speakers including Richard Lankshear, Programme Director at the Future Homes Hub, Mike Leonard from Birmingham University and NHBC’s own Chris Hall, Technical Innovation Manager, feature in the 2024 programme.

A key date in the construction calendar for over 30 years, Building for Tomorrow is an essential event to attend for anyone involved in the housebuilding industry looking to keep up to date with the legislative changes and latest trends in the sector.

Each event will be packed with insightful presentations exploring housing concepts and buildings of the future, the latest on energy efficiency and zero carbon. Informative sessions on MMC, working case studies to show how improvements have been made on existing projects and how changing regulations will evolve through the new standards will also be covered.

Delegates attending any of the Building for Tomorrow 2024 events will get the chance to meet a wide range of exhibitors representing the latest in innovative products, components and technologies to increase their knowledge and help develop their

business. Delegates can also gain CPD learning credits for attending.

Nick Cunningham, Regional Director at NHBC commented: “Building for Tomorrow has always been a stalwart event, but this year I believe it is more on-point than ever. We face numerous legislative changes that affect our industry and keeping up with these, and the resulting technical implications, can be extremely challenging. That’s why this series of events is designed to support the housebuilding industry and deliver helpful and insightful content as well as the opportunity to meet and discuss things with other industry professionals; this is not something we get to do often but it’s vital that we connect and communicate so we can all make progress together.”

For dates, venues and more information go to: www.nhbc.co.uk

NG Bailey Secures NHS Emergency Care Project NG Bailey has secured a £7.6million contract to support the creation of a newbuild Emergency Care Village for Worksop and Bassetlaw Teaching Hospitals NHS Foundation Trust.

The contract will be undertaken in partnership with Integrated Healthcare Projects (IHP) and will see NG Bailey delivering all mechanical, electrical and public health installations on-site. This includes the new Emergency Care Village, as well as the refurbishment of existing clinical and mental health accommodation to create a new Paediatric Assessment Unit and Acute Medical Unit at Bassetlaw Hospital.

NG Bailey and IHP have a long-standing partnership which has delivered many successful complex healthcare refurbishment and new build developments over the past ten years, including working on a new Urgent and Emergency Care Department for Chesterfield Royal Hospital NHS Foundation Trust in 2022.

MMC are being widely used across the project and many of the service installations, including heavy

duty bracketry and spools, plant room skids and distribution boards will be manufactured at NG Bailey’s specialist Offsite Manufacture facility. By using offsite construction techniques, NG Bailey can speed up the manufacture and installation of equipment and reduce the impact of the works on the wider hospital estate.

The scheme will also be an all-electric design, to support the NHS’s drive towards net zero by 2040, as well as building on NG Bailey’s own commitment to its Net Positive responsibility strategy.

Patrick Morrison, Healthcare Sector Director at NG Bailey said: “We have a strong historical working relationship with IHP, so we’re pleased to be continuing our partnership to deliver this important project, which supports our NHS and will create improved emergency care services in the region.

“We have extensive experience in delivering healthcare projects across the UK, working in live hospital sites where maintaining high standards of ongoing patient care is vital. We have worked closely with IHP throughout the preconstruction phases to help develop the design, driving innovative solutions and embracing modern methods of construction which will help accelerate delivery of the scheme, reduce carbon impact, and minimise disruption. We are looking forward to starting work on site soon and seeing the project complete next year.”

A team of engineers, including apprentices, will be onsite to support the delivery of the new development at Bassetlaw Hospital, which will increase the size of the Emergency Department and provide more accessible same day services. The work began in October with the project due to be completed in summer 2024.

Source: www.ngbailey.co.uk

NOVEMBER/DECEMBER 2023 | WWW.OFFSITEMAGAZINE.CO.UK

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OFFSITE AWARDS 2023

SHINING LIGHTS

Bringing together key businesses and industry leaders, the 2023 Offsite Awards rewarded the leading projects, people and products driving forward offsite manufacture and MMC technology – in case you missed it here are the evening’s big winners.

2023 Winners

Celebrating the significant achievements of the industry over the past twelve months, the Offsite Awards – held at the Coventry Building Society Arena on 19th September during Offsite Expo – over 500 guests gathered to celebrate groundbreaking achievements and the pioneers who are developing radical new offsite technologies, innovative product developments and landmark projects using factory-based methods.

The last year has been one of change but also genuine progress.

2023 has seen offsite construction make impressive leaps forward in technology, engineering and design and its visibility is an at alltime high. With an increased focus

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on better performance, streamlined manufacturing and the delivery of safer, greener structures, offsite is helping to advance a better, more sustainable UK construction landscape.

Every year, the awards give an incredible insight into the breadth and complexity of offsite projects across the built environment. The 2023 Awards received over 200 entrants across 23 categories, with many outstanding examples of pioneering projects, innovative products and inspirational people, the judging panel had a tough job selecting the winners from a wealth of worthy finalists.

The awards ceremony – hosted by comedian and TV presenter Lucy

Porter ensured that the celebrations flowed smoothly and were also highly entertaining – offered the perfect opportunity for the finalists to network and discover more about the inspiring entries.

It was a great night for HLM Architects, B&K Structures, Engenuiti and Stora Enso, who took home the coveted ‘Winner of Winners’ award for their project at the National Manufacturing Institute Scotland. The BREEAM ‘Outstanding’ NMIS headquarters is a unique, iconic flagship facility which places Scotland firmly at the front of advanced manufacturing innovation.

Its design and delivery reflect this through the creative use of MMC for greater efficiency through repetitive

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OFFSITE AWARDS 2023

elements, minimised material use and wastage, and opportunity for future expansion. The project is an example of pushing the boundaries of offsite construction to achieve unique, worldclass facilities.

The judges said: “This project is a standout, as befitting its use. The flexible design, range of MMC solutions deployed and recognition of its educational use are truly extraordinary. That this has been achieved while also delivering high quality, statement architecture is a testament to the skills and experience of this worthy winner.” You can read more about this project on p54.

Huge congratulations to all the 2023 winners. You can review them all over the next few pages.

2024 10TH YEAR ANNIVERSARY EVENT The profile and coverage gained by all the finalists and winners has helped propel the sector to another level so if you are proud of your exceptional team, project development or product innovation get prepared for 2024.

The Offsite Construction Awards will return to the Coventry Building Society Arena for their 10th Year Anniversary event on 17 September 2024, alongside Offsite Expo that will be taking place on 17-18 September.

There are 24 categories that cover every aspect of the industry. It is completely FREE to enter both single and multiple categories at the Offsite Awards. Deadline for submissions is Friday 31 May 2024.

Winner or Winners 2023 HLM Architects, B&K Structures, Engenuiti and Stora Enso National Manufacturing Institute Scotland

SPONSORSHIP OPPORTUNITIES The Offsite Construction Awards provides one of the most effective platforms for targeting the offsite industry, presenting the ideal opportunity to maximise exposure and penetrate this economically important market. The 2024 marketing campaign will be launching soon and many of the sponsorship packages will have already been snapped up by savvy companies wanting to gain the full exposure on offer.

To discuss the 2024 promotional opportunities still available please contact the team on 01743 290044 or email: julie.williams@radar-communications.co.uk To keep up to date with developments and find out more about the 2024 Offsite Awards head to www.offsiteawards.co.uk

NOVEMBER/DECEMBER 2023 | WWW.OFFSITEMAGAZINE.CO.UK

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OFFSITE AWARDS 2023 THE FULL LIST OF 2023 AWARD WINNERS ARE...

Architect of the Year HLM Architects - National Manufacturing Institute Scotland

Best use of Concrete Technology PCE - Assembly C

Building Performance Award Saint Gobain - Off-site Solutions

Best use of Hybrid Technology Citu - The Climate Innovation District

Best use of Steel Technology Design4Structures - Lucent

Best use of MEP & Pod Technology Volumetric Modular - Bathroom and MEP Pods

Best use of Timber Technology Engenuiti, Stora Enso, Ryder Architecture and B&K Structures Port Of Tyne O&M Base – Dogger Bank AND STOAS Architects and Aldi Stores Leamington Spa - Low Carbon Store

Best use of Volumetric Technology Algeco - Algeco Delivers Turnkey Solution at £19.2m Leeds Academy Project Using Seismic Platform

BIM/Digital Construction Award Kier Component Tracking in Complex Supply Chains - HMP Millsike

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FOCUS ON

FRAMING

SEMINAR

SAVE THE DATE 14.05.24 BIRMINGHAM

Displaying ground breaking innovation through light steel framing solutions.

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FOCUS ON FRAMING provides the opportunity to hear

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insightful case studies from those who are designing and

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developing the industry’s ground-breaking projects. The

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seminar will be complimented by an exhibition of leading businesses across the sector, and provide networking

• Research competitors’ products and messaging

prospects with those who are shaping the future of the

• Keep up on industry trends

Light Steel Frame industry.

• Meet with key clients

BOOK YOUR EXHIBITION STAND TODAY

IN PARTNERSHIP WITH

To book your stand, contact Julie Williams on 01743 290001 or email julie.williams@radar-communications.co.uk

To find out more or book your ticket please go to www.focusonframing.co.uk or call 01743 290001

OFFSITE AWARDS 2023 Contractor of the Year ES Global - ABBA Arena

Commercial Project of the Year Engenuiti, B&K Structures, Stora Enso and Ryder Architecture Port of Tyne O&M Base – Dogger Bank

Offsite Pioneer Award Oliver Novakovic - Barratt Developments eHome2, Energy House 2.0

Client of the Year Housing 21 - Patent Walk

Education Project of the Year Innovaré Offsite - West Coventry Academy

Engineer of the Year Heyne Tillett Steel Technique Clerkenwell

Healthcare Project of the Year McAvoy University Hospital Birmingham NHS Foundation Trust – Modular Wards AND MTX Derriford Hospital – Royal Eye Infirmary

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OFFSITE AWARDS 2023 Infrastructure Project of the Year Knight Architects - Network Rail Flow Bridge

Private Housing Project of the Year Hawkins\Brown - Portlands Place, Stratford

Installer of the Year Lift and Locate - Wood Wharf Building

Product Innovation Award Explore Manufacturing - Modular Bridges

International Project of the Year Casas inHAUS - Modular Villa and Prefabricated Concrete Cantilever Pool, Valencia

Social Housing Project of the Year Zedpods - Hill Street House

Winner of Winners HLM Architects, B&K Structures, Engenuiti and Stora Enso - National Manufacturing Institute Scotlanddd

Retail / Leisure Project of the Year B&K Structures, Grosvenor, Heyne Tillett Steel and Stiff & Trevillion Newson's Yard

HIGHLY COMMENDED Architect of the Year SHEDKM - Redbridge Quay,Wirral Waters

Engineer of the Year design4structures - One Sherwood Street

Best use of Hybrid Technology Engenuiti - Southmere Library (The Nest)

Offsite Pioneer Award Greater London Authority, Turner & Townsend and Energiesprong UK - Mayor of London’s Retrofit Accelerator-Homes Innovation Partnership (RA-HIP)

Best use of Timber Technology B&K Structures, Mepc, Bowmer & Kirkland, Stora Enso and Simpson Haugh - Noma Pavilion Marketing Suite BIM/Digital Construction Award John Sisk & Son - Offsite Manufacturing Facade Panel Progress Reporting Client of the Year Mid Devon District Council - ZeroCarbon Social Housing Schemes on Brownfield Sites Commercial Project of the Year Engenuiti, KLH & HOK - The Family Kitchen and Shop at London’s Royal Botanic Gardens, Kew

Private Housing Project of the Year SHEDKM - Redbridge Quay,Wirral Waters Retail / Leisure Project of the Year Stoas Architects and Aldi Stores Leamington Spa - Low Carbon Store Social Housing Project of the Year Energiesprong - Becontree Deep Retrofit Pilot OFFSITE AWARDS 2024 Deadline for submissions is Friday 31 May 2024

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CASE STUDY

HEALTHCARE

SMARTCARE OPTIONS 2023 WINNER

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2 Healthcare Project of the Year at the 2023 Offsite Awards was won by McAvoy for its role in delivering urgent ward space at two of University Hospitals Birmingham’s (UHB) hospitals.

Receiving the largest number of COVID-19 patients in the country at the peak of the pandemic, the two modular 48-bed wards at UHB’s Good Hope Hospital and at Heartlands Hospital was instrumental in enabling the Trust to boost capacity and tackle waiting lists following the impact of the pandemic.

McAvoy worked collaboratively with the Trust to design and configure the SmartCare modular solution to make the best use of the available space on both sites.

The ward buildings, which have been delivered on a ten-year rental contract to the Trust – thereby saving significant capital expenditure outlay – utilised the very latest in precision manufacturing

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3 techniques and further reinforces McAvoy’s credentials for high quality, fast delivery, and sustainability in the healthcare sector. It took just 14 weeks from the delivery of the first module to handover of the wards at Good Hope Hospital, with the Heartlands project completed in 18 weeks. Speed of delivery was crucial to minimising disruption to patient care, with both projects being delivered on live hospital sites.

“The modular wards were the right choice for us to provide additional ward space to enable us to provide much needed additional care to our communities following the impact of the COVID-19 pandemic,” said Richard Truman, Estates Development Manager, University Hospitals Birmingham NHS Foundation Trust.

“It was a huge achievement to work with McAvoy to deliver the project so quickly and with minimal disruption, which was vital to us as the wards were being installed in a live hospital environment.”

University Hospitals Birmingham NHS Foundation Trust is recognised as one of the leading NHS trusts in the UK, employing more than 20,000 members of staff across its locations at Good Hope Hospital, Heartlands Hospital, Queen Elizabeth Hospital Birmingham, and Solihull Hospital.

Tomas McNicholl, Senior Contracts Manager at McAvoy added: “We are delighted to have won this award in recognition of the important role the new wards play in enabling the Trust to cope with the increased demands on its services and the impact from COVID-19. The use of our SmartCare modular solution ensured rapid delivery of healthcare facilities that are high-quality, sustainable and flexible.

It also provides the Trust with increased flexibility, allowing for relocation of the modules in the future, if necessary.”

This is the latest in a series of major projects delivered by the leading offsite manufacturer across the health and education sectors including Merstham Park School, a pioneering ‘Low Carbon Pathfinder’ project for Department for Education, two SEND classroom blocks for Southampton City Council, a GP Out of Hours surgery for Southern Health and Social Care Trust in NI and a four classroom SmartClass block at Castlepollard Community College in ROI. McAvoy’s expert SmartCare team has extensive experience in the delivery of patient and servicefocused solutions to help address the growing need for flexible, fit-forpurpose accommodation. McAvoy’s standard and bespoke healthcare offering ranges from complete hospital buildings to ward extensions, operating theatres, endoscopy suites, laboratories, same day emergency care (SDEC), ambulatory & emergency care facilities, GP surgeries & health centres and office accommodation.

For more information visit: www.mcavoygroup.com Images: 01-03. The SmartCare team and offsite delivery brought huge efficiency to delivering the new healthcare facilities

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HEALTHCARE

DIAGNOSIS MODULAR

Algeco, in partnership with Hygieia, has developed a new range of standardised Community Diagnostic Centres (CDCs) using its revolutionary platform design modular construction system.

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3 Demand for diagnostic tests continues to increase as more than 85% of patients seeking NHS care now require this service. Finding out what is wrong with a patient is vital to treating them as early as possible and as of April 2023, around 1.6 million people in England were waiting for a diagnostic test. This waiting list has been growing steadily since 2008.

The UK currently has less diagnostic equipment than comparable countries: it has 8.8 CT scanners per million population, 25th out of 28 OECD countries, and the number of MRI units and PET scanners are also below average. NHS England estimates that demand for CT scans will rise by at least 100% in the next five years.

Hygieia – a consortium of leading companies that have wide experience of creating efficient, modular buildings

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for the healthcare sector – now offers a range of three standard sizes for CDCs: small, medium and large, based on Algeco’s platform design modular construction system.

The new CDC’s deliver a more cost effective, rapid build solution to NHS Trusts and the private sector. They are offered with a full design, delivery, construction and finishing service, so that customers can start using their CDC from day one. They also incorporate all servicing, including specialised electronics needed for sensitive imaging equipment. The CDCs provide local communities with fast and flexible access to a range of checks, scans, and tests closer to home. They reduce the number of hospital visits and reduce waiting times for patients by diverting people away from hospitals.

Algeco and Hygieia’s ability to offer a full turnkey solution was achieved by partnering with some of the leading brands in the sector, such as Tata Steel, P+HS Architects and CAD21, amongst others. The CDCs are fully compliant with HTM / HBN requirements.

James Withey, Managing Director at Algeco Offsite Solutions (OSS), said: “Working in partnership with Hygieia, our new CDCs provide a step change in healthcare provision by supporting the Government’s aim of delivering services directly into the community.

Lean manufacturing and Design for Manufacturing and Assembly (DfMA) through our revolutionary platform design are central to reducing timeto-market and enhancing value of the CDCs.” A spokesperson from Hygieia added: “Our experienced healthcare design teams have meticulously designed and developed a small, medium and large version CDCs. These standard formats have been developed to utilise Algeco’s platform design modular solution. We have done the hard work, so our customer doesn’t have to.”

For more information visit: www.algeco.co.uk/temporary/sectors/ healthcare Images: 01-03. The CDCs were unveiled at the Health Estates event, Manchester and deliver all the benefits of modular construction whilst providing faster and more convenient diagnostic services to patients locally

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BATHROOM & ENSUITE PODS

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Designed, engineered and manufactured by our multi awardwinning offsite experts.

HOUSING

DELIVERING MMC FRAMEWORKS

Dean Fazackerley, Head of Technical Procurement at LHC Procurement Group, explains some of the steps they have taken to better understand offsite manufacturers through using real-time factory assessments.

1 Despite modern methods of construction (MMC) being increasingly recognised as a way to deliver quality housing at pace, the takeup has been modest owing to some trepidation within the public sector. This could be down to a misunderstanding of the barriers to entry into MMC, and complications with procurement constraints. It can be seen as an expensive luxury, with many manufacturers working to their own designs, and complex to manage with new supply chains and stakeholders to work with. We have also heard the perception that public procurement constraints limit a local authority’s ability to develop the right relationships required for MMC. However, through framework agreements, contracting authorities can manage this process much more easily, with a single point of contact and access to technical expertise that

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aligns with all RIBA Plan of Work 2020 stages, from the initial stages through to design, construction, handover, and use.

Dedicated MMC frameworks Earlier this year, our Modern Methods of Construction of New Homes (NH3) framework went live. It has been shaped by extensive engagement with housing contractors and manufacturers and allows for a range of housing types, from low rise and medium/ high rise, through to specialist accommodation such as care homes.

The framework also provides for delivery of ‘room in the roof’ projects and adaptive pods. Framework agreements like this allow relationships to flourish over a longer-term period and help set out an integrated supply chain. We see it as a vital tool to drive programmes for low-carbon, modern homes for housing associations and local authorities across the country.

Quality assessments Our commitment to becoming a Gold Standard framework provider means that as part of the development of NH3, we conducted an in-depth assessment of all potential suppliers.

This began with a questionnaire tailored depending on the workstream.

To evidence their capability to deliver MMC projects for the workstreams they had applied for, framework applicants were quizzed on everything from what training they provide staff with to how they demonstrate KPIs, and how they monitor customer feedback during projects.

Following this, we spent a day on-site with each manufacturer to conduct in-depth factory assessments to assess their factory process. Scores were added together, and those who scored the highest were awarded the highest allotted award.

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SUPPORTING THE DELIVERY OF MMC PROJECTS THROUGH OUR MODERN METHODS OF CONSTRUCTION NEW HOMES (NH3) FRAMEWORK

Building your community matters to us...

Our frameworks are procured in accordance with The Public Contracts Regulations 2015 and are free to use. They provide public sector organisations with easy access to procure works, products and services for the construction, refurbishment and maintenance of social housing, schools and public buildings.

LHC Procurement Group strives for excellence in the services provided to their clients and aims to deliver the best solution to suit every project’s individual needs.

www.lhcprocure.org.uk

Our dedicated Client Support and Project Support teams are on-hand to assist throughout the life of the project.

For more information on how our frameworks can work for you, get in touch.

HELPING YOU TO BE MMC READY

HOUSING

Applicants were scored for the following:

• Quality of products – including structure, cladding, finish, and M&E installation, throughout the construction process from goods in down the production line to storage and dispatch • Pre-manufactured value – what level of automation is used throughout • Environmental and waste management – what measures were taken to minimise environmental impact and waste management.

For example, how do they reduce energy usage on premises in terms of heating and lighting? How do they manage water usage during manufacturing and in the offices?

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Which materials are they using in manufacturing? And are there any EV charging points available to use?

• Process management – we observed the quality control process for elements down the production lines, how products are marked up on the production line, the worksheets for products, and inspection and signoff at each stage • Quality of temporary weather protection during storage at the factory/on-site and transportation.

MMC. Fortunately, we are seeing local authorities beginning to look past the barriers to entry to see the value MMC can bring: our NH2 framework led to a pipeline of nearly 5,000 MMC homes across 133 projects. The government’s push towards MMC in its policies – especially the Affordable Homes Programme – should see this figure increase further.

Appetite for offsite One thing that was evident during the assessment process was the sheer passion among industry professionals who want to champion and promote

For more information about LHC and its NH3 framework visit: www.lhcprocure.org.uk Images: 01-03. The new NH3 Framework has been shaped by extensive engagement with housing contractors and manufacturers and allows for a range of housing types

NH3 FRAMEWORK LHC’s New Homes (NH3) Framework will look to deliver £1.2billion-worth of modular homes. NH3 will be delivered through LHC London and South East (LSE), Scottish Procurement Alliance (SPA), South West Procurement Alliance (SWPA), Consortium Procurement Construction (CPC), and Welsh Procurement Alliance (WPA).

“NH3 is a vital addition to support more programmes to build low-carbon, modern homes from housing associations and local authorities across the country,” says Dean Fazackerley. “It will adopt MMC and offsite techniques to produce energy efficient homes for the communities they serve.

“NH3 has been developed to be a market-leading framework providing a wide range of systems and project delivery models to give public sector organisations the flexibility to deliver MMC projects the way they want. With the range of manufacturers and contractors appointed to this framework, NH3 provides an excellent choice for clients to access a range of MMC solutions and providers and is built to facilitate greater collaboration between suppliers and the public sector.”

Through NH3, LHC is looking to support the public sector to increase the use of modern methods of construction and deliver low and net zero carbon homes with high levels of pre-manufactured value (PMV). It will support social housing providers in addressing some of their new housing challenges around the need for sustainable methods of construction and a greater supply of housing stock that is environmentally fit for the future.”

NH3 fulfils a key LHC guiding principle to increase the public sector’s access to regional and local supply chains, encouraging SME involvement and driving economic uplift to regional areas. The NH3 framework runs until 1 May 2027.

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Disclaimer: While Fusion provides advice and data on fire protection to its structure, the Company does not provide any guarantees or warranties for fire protection. Fusion is not responsible for the overall fire performance strategy and project-specific detailing of a building, nor the fitting of the components which provide this protection. Advice should always be sought from a suitable qualified and experienced fire engineer on any aspect of a project which may affect a building’s performance in a fire.

19 - 20 MARCH 2024

COVENTRY BUILDING SOCIETY ARENA

Join the conversation and connect with key players MODULAR MATTERS 2024 raises the bar, building on the successes of previous events, while diversifying and expanding our

programme and exhibition offering for a wider audience. With a brand-new venue, the 2024 event will provide a more interactive and engaging platform that encourages active delegate participation through facilitated engagement and discussion.

Lifting the bonnet to get to the brass tacks, taking lessons from global benchmarks and international best practices.

MODULAR MATTERS is an opportunity to join the conversation

and connect with key players in the sector as well as suppliers, manufacturers, architects and decision makers from local authorities and the public sector.

WE ARE CURRENTLY RECRUITING OUR 2024 SPEAKERS

If you would like to be considered to present at Modular Matters 2024,

please email your name, company and proposed presentation title and description to ellie.guest@radar-communications.co.uk

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To enhance your presence at Modular Matters book an exhibitor or sponsor package.

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For more information on the promotional opportunities available call 01743 290042 or email julie.williams@radar-communications.co.uk

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Previous Event Contributors Include:

JOIN THE CONVERSATION HAVE YOUR SAY! To find out more and book your place at this essential fast-track construction conference and exhibition go to:

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EDUCATION

HOW TO FAST-TRACK SCHOOL BUILDING PROGRAMMES

With the recent focus on unsafe and ageing school buildings compounded

by RAAC issues, Jackie Maginnis, Chief Executive of the MPBA, discusses how a volumetric approach could provide many remedies. that an estimated 700,000 children are being taught in ageing or unsafe school buildings in England, and that the deteriorating condition of school buildings is damaging pupil attainment and teacher retention. We need a fast-track approach to get this 10-year programme back on track. Without doubt this is a massive undertaking, but by using innovative construction methods – it is not unsurmountable.

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2 UK schools are facing yet another unprecedented challenge. As teachers and education leaders fight to get learning back on track, their efforts are now hampered by unsafe structures and a severe lack of alternative learning environments. In the latest list published by the Department of Education (DfE), 174 schools have already been identified as affected by using dangerous reinforced autoclaved aerated concrete (RAAC) in their buildings.

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RAAC is a lightweight material that is a cheaper alternative to standard concrete but was found to be less durable and with a shorter life span.

Some affected schools are having to move to remote learning and others having to change the way they operate to avoid certain areas.

Back in January 2020 the Department for Education (DfE) launched the £3billion offsite framework, also known as MMC1. The National Audit Office (NAO) reported in June 2023

As an early adopter of modern methods of construction (MMC), after the war the government used latent munitions factory capacity to cope with a rapid increase in the need for education buildings as a result of the post war baby boom. This was very much the development ground for MMC – backed by thinking way ahead of its time.

Government support has resulted in a significant pipeline of work which has generated more investment and innovation in the volumetric modular sector – advancing the technology and increasing manufacturing capacity.

MMC1 together with the requirement to achieve at least 70% PreManufactured Value (PMV) is a driving force in the specification of volumetric technology in public sector projects – particularly in the education sector.

As the name suggests, PMV is the financial proportion of a project’s gross construction cost derived through pre-manufacturing. It is a core metric for measuring the level of MMC in a project and is central to the UK government’s procurement programme. Contractors are required to show that pre-manufacturing will account for at least 70% of all construction costs. This essentially plays to the strengths of a volumetric modular approach.

Increasing productivity is crucial to success. We have the technology,

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EDUCATION capabilities and capacity, so how can this be achieved? By taking the building process ‘offsite’ into quality-controlled manufacturing environments whilst simultaneously, ground and foundation works can be carried out onsite. This approach not only delivers productivity gains but enhances the quality of the final output. Modular construction is a highly organised and streamlined process that can see construction project times reduced by 50% - 60%.

We must bring a manufacturing mindset to the design and construction of school buildings.

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With volumetric manufactured buildings all construction data can be validated and co-ordinated as part of a structured process, which helps provide accurate and reliable information for clients at the point of handover. Volumetric construction also

helps ensure client satisfaction and offers product assurances through the certainty and quality embedded into the manufacturing process.

MPBA The Modular and Portable Building Association (MPBA) plays a key role in supporting all sections of the industry. Leading best practice principles, the association is represented on many committees for the benefit of members. The MPBA ensure evolving government policies and decisions are not made on behalf of the construction industry without due consideration for the impact they may have on the volumetric modular sector. Regardless of the size and type of your business, becoming an MPBA member will open doors to valuable business development, training, and collaboration opportunities.

For more information visit: www.mpba.biz

Providing a predictable pathway for new education buildings is what is required for parties involved. Not only do the benefits of volumetric manufactured buildings begin in the factory, but they also continue to the construction site and last through the lifetime of the building.

Images: 01. Riverside School. Courtesy Portakabin 02. Archbishop Holgate’s School. Courtesy Portakabin 03-04. Douay Martyrs School. Courtesy Premier Modular

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DFMA

PLATFORM FOR CHANGE

Digital tools, ‘kit of parts’ solutions and Design for Manufacture and Assembly (DfMA) are central to the future of offsite manufacture.

Charlotte Garrett, DfMA Lead at KOPE, told us some of the reasons why.

1 Q: Can you give a little background to KOPE – what is its role in the offsite sector and how is it driving change for its customers/users?

Charlotte Garrett (CG): Kit of Products Engine (KOPE) is a purpose-built software platform for the offsite construction industry which is bridging the gap between suppliers and specifiers. It makes it easy and simple to integrate real construction products into our project design models, facilitating collaboration, and informed decisions from the beginning and throughout a project lifecycle.

Q: The use of digital tools is central to offsite manufacture with a plethora of toolkits, platform approaches, repeatable components, and harmonised design – how are these developing an Industry 4.0 approach?

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2 CG: The combination of the product platform approach and digital technology enable us to create greater economies of scale, quality, and consistency from the ground up. We achieve this by aggregating demand in a kit of parts, where each part has structured and standardised information about its size, performance, and how it connects with other parts. They can then be seamlessly translated into the digital kit of products through their structured and standardised information, making co-ordination straightforward and reliable. Digital technologies will enable us to embed a rule book into the digital products, controlling how that product can and cannot be configured and assembled when we integrate them into any project, and we can do that automatically.

We empower both designers and

suppliers to make informed decisions on both the design and practical application for their projects.

Q: Improving productivity is a common concern across the construction sector – how can factorybased manufacture and a DfMA approach improve these productivity levels?

CG: With an aging workforce, outdated methods of working and a fragmented supply chain, we need to adopt offsite solutions using the product platform approach. We can give suppliers visibility into future pipelines so that they can anticipate and develop standardised products at scale with tailored customisations that respond to the demand. This creates greater economies of scale that can maximise the efficiencies in digital automations

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DFMA

3 and lean manufacturing for the design and make processes.

Q: Decarbonisation is critical across the construction industry generally – how can technology address the many issues surrounding the circular economy, waste reduction, embodied carbon and overall sustainability?

CG: By leveraging digital tools like KOPE, we don’t just place products into your design files, but configure and optimise them using our optimisation engine. KOPE can generate many options based on a product’s rules around application and surface the best options relating to your goals, such as lowest embodied carbon, number of panels, or the least waste. We do this by maximising the use of standard board sizes making use of the offcuts and reducing the number of types to increase standardisation.

Q: Standardisation, harmonisation, optimisation – do you feel there needs to be some kind of simplification of these concepts? What barriers to understanding do you encounter when discussing DfMA? CG: The most effective way to communicate is through demonstration and worked examples. Standardisation is often

a misunderstood term. Designers typically model buildings to a low level of detail with descriptive specifications based on aesthetic and performance, which means they tend to associate standardisation to those attributes which isn’t the case. Standardisation in offsite construction is about process, creating efficiency through repetitive tasks, not necessarily repeated parts that look the same.

When the UK Government consolidated the demand across a broad portfolio of projects and examined the space requirements based on activities, occupancy and frequency, they identified just 170 unique space types between all the schools, hospitals, housing and prison programmes. 50% of all the spaces were common spaces such as hallways and bathrooms, with a significant majority sharing a consistent 8m width. This data tells us that our built environment is already quite standard with ample scope to use repeated elements whilst still being able to create unique yet efficient buildings.

This data tells us that our built environment is already quite standard with ample scope to use repeated elements whilst still being able to create unique yet efficient buildings.

Q: A criticism often levelled at offsite is the lack of interoperability amongst systems and providers in the event of failures and this is putting off clients and developers – is that a genuine worry and how can it be overcome?

CG: We do need to invest more in defining the different offsite technologies. So that we can begin to standardise how they interface with one another and develop robust details, so that we can simplify and standardise testing, regulation, and inspections as well as interoperability and interchangeability of systems.

There really isn’t as much variability as we might think within each of the different technologies and by investing in some standards – a point of reference – we would quickly see that a large portion of the suppliers would be able to align to one of them.

Q: The Golden Thread attempts to connect the fields of design, manufacturing and delivery with the huge volumes of data generated during a project together – how can this data be used to its maximum potential to prove the benefits behind offsite and DfMA choices?

CG: By using Building Information Modelling (BIM) and the use of the data across the lifecycle of a project will be crucial for clients to understand and use their assets effectively.

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DFMA

4 but a smart digital product. One that also embeds a digitised rule book that dictates how the product can be configured when integrating into projects.

Q: KOPE and Cast have developed MMC Market – a product information portal – what were the drivers behind this development?

CG: We wanted to increase the visibility of offsite construction products and simplify the search process for specifiers. We also wanted to showcase the great work and experience within the sector and build greater confidence, so that the construction industry can invest in innovative solutions such as developing a kit of parts and the products that are going to build our future environment.

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Q: How do you see the offsite landscape changing in the next 18 months? How far can the digital transformation of the offsite sector go?

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CG: Picture an open digital platform, a centralised hub, where designers can explore the entire offsite construction sector for suppliers, case studies, and products – making it easy to find and use the right materials and products for any project. Where suppliers provide a digital version of their products, with structured and standardised information that perfectly aligns to the structured information in your kit of parts, for seamless integration into projects. Also, not just a static downloadable digital product,

‘Productisation’ is about transforming design and build processes into standardised and replicable products. It is about streamlining the creation of building components in both design and application, by turning them into well-defined parts physically and digitally, ensuring quality and consistency. This will make it straightforward and reliable to integrate offsite products into projects.

It shifts the focus from traditional one-off designs to a standardised approach where designers work with prefabricated products and their known capabilities, increasing efficiency and cost savings. It does require a shift in mindset, to be more adept at utilising these standardised elements creatively to achieve unique and functional buildings.

For more information visit: www.kope.ai Images: 01. Charlotte Garrett, DfMA Lead, KOPE 02-03. KOPE’s digital development of product information is part of the wider DfMA approach to offsite manufacture 04. Factory manufacture has technology embedded into its future. Courtesy TopHat 05. A kit of parts sees each part given structured and standardised information about its size, performance, and how it connects with other parts of a building

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

BRITISH OFFSITE FACTORY TOUR

FRESH HORIZONS

British Offsite opened the doors to its new state-of-the-art Horizon factory recently, to show visitors first-hand, how they are bringing robotics and streamlined production processes to panelised light gauge steel design.

British Offsite worked with the Manufacturing Technology Centre (MTC) to help scope out Horizon, with mapping exercises, layout advice and used the existing Skyline facility to help inform its decisions on the production line. When working at full capacity in 2025, the new factory will look to deliver 110,000 linear metres of its UNIsystem with an aim of creating 4,000 homes per year.

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2 Over 50 visitors from all parts of the building industry were shown around the new 180,000sq ft factory as part of the Explore Offsite factory tour programme. Horizon is the second British Offsite factory and follows on from its Skyline facility – both based in Braintree, Essex.

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Opening in July 2023 and now fully operational, Horizon was three years in the planning and construction, and was designed in collaboration with Swedish robotic engineering firm Randek AB and has seen an overall £45million investment including £6million on the hyper-modern production line.

Advanced manufacturing The completed factory looks superb with a glass and Trimco-panels façade with solar panels on the roof helping reduce energy costs and deliver wider sustainability benefits. There are also special energy monitoring systems to review factory production capacity.

Alongside the triple-height main factory floorspace containing the production line, there is 1,860sq m of office space, R&D suite and staff welfare facilities including a canteen and healthscreening clinic.

After a company overview presentation, visitors were given a full tour of the production floor so they could see for themselves how British Offsite are approaching a fabric first approach to building design.

Launched in 2020, British Offsite are developing both a product and process driven model – central to this being a manufacturing mindset and the adoption of robotic technology.

The sensor-guided robots ‘transport, grab, cut, drill, nail, screw, weld, glue, fill, spray-paint’ and are developed specifically for the construction sector to make and assemble the light gauge steel panels.

The robotics ensure precision cutting and assembly for every component plus they reduce waste and damage through poor handling. This process is helped with multi-skilled operatives

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BRITISH OFFSITE FACTORY TOUR

3 across the different stations working on the panels and monitoring them through the production line. The ‘semi-autonomous’ approach guarantees that products being manufactured offer high quality, repeatability and a reliable standardised panel. All panels are subject to rigorous testing and quality control with a ‘hospital lane’ carrying out any remedial work before panels are stored, wrapped and prepared for transport.

“We want to speed up our client’s construction phase and help them realise the 20-30% programme savings and quicker return on investment that offsite delivers,” said Richard Bacon, Business Development Manager. “You can build in many efficiencies through the manufacturing environment. Doing it in the factory makes perfect sense – we know we can deliver what we are saying we can deliver.”

Precision 2D systems The Horizon factory produces British Offsite’s panelised UNisystem range.

These light gauge steel closed panels have windows, doors, thermal and acoustic insulation, vents and fire stopping factory-fitted and are a ‘complete’ panel. The UNisystem range comprises of infill and load bearing panels, with wall and floor options available. They can be manufactured to a maximum height of 3.2m and a maximum length of 8.4m but panels outside of these sizes can also be produced. Panels come with fixings applied for a range of external finishes including brick ties for brickwork, brackets for cladding or brick slip systems or a mixture to support a combination of finishes.

It is an adaptable system for a range of sectors. Although the present focus is on residential projects, the production line is not limited to housebuilding and has the capacity to extend to school buildings, healthcare facilities and student accommodation. British Offsite are already in discussions about providing solutions for the education sector.

You can build in many efficiencies through the manufacturing environment. Doing it in the factory makes perfect sense – we know we can deliver what we are saying we can deliver.

Shaping up future delivery An example of UNisystem success can be seen at Abbey Quay, Barking.

This new £18.9million urban riverside project in the London Borough of Barking & Dagenham has 13 residential blocks ranging from 7 to 29-storeys in height. The sixacre, 1,000 homes scheme will be delivered over the next five-years. For the superstructure, the project team at Abbey Quay utilised 7,500 linear metres of UNipanel, complemented with 5,700 linear metres of UNiwall, the internal closed panel pre-fitted with insulation, doorways, MEP and service void battens.

Speaking earlier in the year, Shaun Weston, Managing Director of British

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BRITISH OFFSITE FACTORY TOUR

5 Offsite said he was proud to be part of the new wave of high-tech British manufacturing, bringing significant new capabilities to the UK construction industry saying: “We've created one of the most automated light gauge steel panel assembly lines in Europe.

The new robotic production line at Horizon allows for the consolidation of the work of up to five trades into one panel. Our MMC products are designed to be easily integrated into existing projects, helping to streamline traditional residential construction.”

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Wrapping up the Horizon tour Shaun Weston led a Q&A session and was hugely positive about the future of the factory and UNisystem saying: “We have lots of capacity potential, but we want to spend the next two years taking sensible meaningful steps. The number one most important thing to us is ‘let’s make it safe and make sure its quality’ – that’s very much our ethos.”

Advanced manufacturing, delivering quality precision products through a repeatable process is why offsite/MMC works. Presently, the factory is busy supplying products to Weston Homes projects but is ramping up production with an ongoing process to streamline the assembly of every component and maximise efficiency even further.

The new Horizon factory is certainly impressive and is arguably one of the most advanced in Europe dedicated to manufacturing light gauge steel systems. It is also emblematic of the potential that offsite construction holds for the built environment and the future of UK manufacturing.

For more information visit: www.britishoffsite.com

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Images: 01. Horizon Factory, Braintree 02-05. Visitors were shown all aspects of the light gauge steel frame manufacturing process including the advanced robotic production line 06. Shaun Weston, British Offsite's Managing Director

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

BE INFORMED GAIN INSIGHT PROVIDE INFLUENCE

With the implementation of the Building Safety Act, it is imperative that the industry is informed.

Whilst the construction industry is grappling with the implications of the Building Safety Act, the LSFA is helping our members to get across the detail.

Membership also provides a variety of benefits derived from forward-thinking strategy, a dedicated steering group and the drive to shape the future of the light steel frame sector.

Change is coming… be part of it.

Join the LSFA today!

Call: 01743 290 001 Email: info@lsf-association.co.uk

WWW.LSF-ASSOCIATION.CO.UK

CASE STUDY

VOLUMETRIC MODULAR

CROYDON HIGH LIFE

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1 Leading volumetric developer Tide working alongside Vision and HTA Design, have completed a landmark 937-home, multitenure development in Croydon, comprising of two buildings and once again proving the value of offsite manufacture to the housing sector.

Completion of construction in October was two months ahead of schedule, further enhancing returns for investors Oaktree Capital Management and operator Outpost Management. The market-leading development features the UK’s most extensive range of BTR amenities while also being the largest co-living asset class scheme to have been approved by the Greater London Authority.

The completion of College Road brings the number of homes delivered by volumetric specialist Tide in the borough to 1,483, following the completion in 2020 of neighbouring scheme Ten Degrees, with the two developments combining to boost urban renewal.

“It's fantastic to see this landmark development come to completion after only 28 months, two months ahead of schedule,” said John Fleming, Chairman of Tide and Vision. “College Road demonstrates the many benefits that come with building volumetric and its capacity to transform constrained sites into valuable real estate, but most importantly, providing nearly 1,000 homes and a revitalised public realm for Londoners delivered in an efficient and sustainable way. College Road is a milestone development that highlights our strong partnership with Outpost Management and Oaktree Capital Partners.”

The College Road development near East Croydon train station sees the two buildings – a 50-storey build to rent (BTR) development with 817 one-bedroom and studio apartments, and a 35-storey building providing 120 affordable homes. The 50-storey, 163m building is also Europe’s tallest volumetric modular tower. Until now this record was held by another of Tide’s developments, neighbouring Ten Degrees, which includes a 135m tower and was completed in 2020.

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As both developer and contractor for College Road, Tide worked alongside its sister company and volumetric manufacturer, Vision,

3 using an approach that cuts traditional construction time by up to 50%. The efficiency of Vision’s offsite technology resulted in 73% of the entire developments floor plate being installed in 32% of the programme, helping to achieve the 28-month schedule. This technique with its efficient construction logistics enabled the delivery of 937 homes on the constrained 2000sq m site. The development was designed by Tide and Vision’s in-house design teams in collaboration with architects HTA Design.

“College Road is the product of extensive research into successful models for high density shared living and is the first project to be approved under the GLA’s Co-Living policy,” said Simon Bayliss, Managing Partner at HTA Design. “Every aspect of the development was designed to offer residents the most liveable private space, whilst also having the free enjoyment of truly fantastic communal facilities. The building connects East Croydon to the new cultural quarter through a colonnade enlivened by crafted public art, an integral part of the building’s striking architecture.

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

VOLUMETRIC MODULAR "The design embraces the optimism of Croydon’s midcentury heritage including Richard Seifert’s iconic NLA building, whilst complimenting the neighbouring Ten Degrees, also designed by HTA with Tide and Vision, whose volumetric system enabled faster, more sustainable and higher quality construction.”

Enclave: Croydon The 50-storey tower, now open and operating as Enclave: Croydon, was completed in partnership with Outpost Management and funded

by Oaktree Capital Management.

Enclave: Croydon offers a mix of studios and one-bedroom apartments in a range of sizes, available on an all-inclusive basis with flexible tenures.

By redefining this asset class, the scheme will provide seven floors of carefully curated, expansive amenity space, marking a significant milestone in the development of this emerging residential typology.

Designed by architects Tigg + Coll in collaboration with Outpost Management, the high-quality interiors are complemented by over 30 innovative amenity spaces. These include dedicated entertainment and wellbeing spaces, a podcast studio, multifaith space, spa complete with steam room and sauna, high-end gym, show kitchens, co-working and conference rooms, all topped by a Sky Garden across the 50th floor.

The scheme demonstrates the strong design flexibility and exceptional quality of architecture that the Vision system delivers, as well as the ability to build at record-breaking heights. With Enclave: Croydon, Tide has beaten its own record set at neighbouring Ten Degrees, which, at 44-storeys, became Europe’s tallest modular building when completed in 2020.

Troy Tomasik, Outpost Management founder and CEO, said: “We're immensely proud to have completed Enclave: Croydon and to have welcomed our first residents to their market-leading new homes. Designed to meet the evolving needs of today’s renters and deliver effortless living, our development sets a new standard for the UK rental market, offering unparalleled convenience-led, techenabled studio living on an all-inclusive

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basis. Nowhere else in the UK can you find the range of features available here, combined with beautifully designed apartments, in a supremely connected location.”

College Road forms part of the volumetric-driven urban development of Croydon. Including Ten Degrees and College Road, Tide and Vision have provided close to 1,500 homes, amenity, and commercial space, further enhancing the neighbourhood, and adding to the regeneration of Croydon.

Volumetric construction unlocked the viability of these major sites which sat idle for many years, adding to the area’s housing stock and overall vibrancy. For both companies, this completion builds on a substantial track record of delivering highquality volumetric developments and strengthens the companies’ longstanding partnerships with its funders and investors. This success is based on a robust business model which combines developer, contractor, and volumetric manufacturer. Tide and Vision have a strong future pipeline, with over 3,500 homes currently onsite.

Affordable homes The 35-storey tower contains 120 one-, two- and three-bedroom apartments, ranging from 51-85sq m, community space across two floors, and a roof terrace on level 35. These much-needed affordable homes will be available on a Discount Market Rent (DMR) basis. The homes provide beautiful views and benefit from high-quality finishes, as well as the Vision volumetric system’s high levels of acoustic insulation, soundproofing them from the busy urban environment.

The development includes a glazed colonnade featuring artwork designed

by London artist Adam Nathaniel Furman. Comprising three-dimensional porcelain tiles, which are wrapped around the building, the colonnade links to a wider network of landscaped public routes between East Croydon Station and the cultural quarter providing direct links to central London. The 7m-high arcade adds a new, beautifully crafted streetscape to the city.

For more information visit: www.tideconstruction.co.uk www.visionmodular.com www.outpostmgt.com Images: 01-03. College Road is breathing new life into Croyden. Courtesy Tide and Apex Drone Photography 04-05. The development includes a glazed colonnade featuring artwork designed

by London artist Adam Nathaniel Furman.

Courtesy Taran Wilkhu

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CASE STUDY

STRUCTURAL TIMBER

WORKSTACK COMPLETES WITH CLT

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1 dRMM have completed Charlton WorkStack, a pioneering new model for high density industrial space on compact sites and is primarily constructed from mass timber.

The client, Greenwich Enterprise Board (GEB), are a social enterprise developer providing affordable workspace in the borough of Greenwich, south-east London.

WorkStack answers a growing socioeconomic need for industrial capacity while challenging the generic, land hungry, ‘tin shed’ default of light industrial buildings. Many London Boroughs have de-restricted industrial land which is inevitably acquired for residential development, forcing production away from city centres. Designed to be affordable to rent, operate and maintain, these workshops encourage manufacturing in central London.

WorkStack’s 14 units vary between 55 - 110 sqm (600 - 1,200sq ft) offering tenants choice and growth within the building. The units provide workspace for approximately 60 people, equating to a density of 428 employees per hectare compared to the London industrial average of 69 employees per hectare. Occupiers include furniture makers, knitwear producers, workwear manufacturers and a bicycle/ motorcycle workshop.

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The distinctive cantilevered form gives the building a powerful presence on the adjoining arterial road with a minimal footprint, the progressive overhangs working as both solar shading and covered delivery area. In keeping with the ‘log stack’ inspiration for the form, the material palette is simple. An engineered mass timber structure with limited steel, polycarbonate, glass and rubber introduced only where function or regulation demanded. Each building element is designed to be as efficient as possible – a direct design without excess of any kind.

“Why should ‘light industrial unit’ mean an ugly, cold metal shed with bad light and no view out?” says Alex de Rijke, founding director of architects dRMM. “WorkStack is a demonstration of a new kind of tough timber workspace that is warm, bright and practical. It also gives a powerful message that light industrial can mean socially and environmentally inspirational.”

WorkStack is on track to be BREEAM Excellent. The cross laminated timber (CLT) stacked structure sequesters 343 metric tonnes of carbon, with around 21% less upfront embodied carbon than LETI’s 2030 Design Target (of 350kgCO2 /m²), and 44% less than RIBA’s 2030 Built Target for whole life carbon (of 750 kgCO2 /m²). The panelised construction reduces time on-site, creates a safer and cleaner working environment and minimises material waste. The loadbearing

timber walls and ceilings are exposed throughout. This beautiful and economical solution eliminates the need for additional internal finishes, reduces associated material resources and environmental impacts, whilst offering biophilic benefits to users.

“I first contacted dRMM when searching for new approaches to the building of urban workspace,” says Michael Finlay, Director, GEB. “I was extremely lucky, because I found there a wealth of experience and expertise in the use of timber and particularly of CLT. After a period of thorough planning and development, the Charlton Workstack was devised and eventually built – it now provides outstanding accommodation for fourteen SMEs in an area where space is becoming increasingly scarce.

I believe that dRMM have part of the answer to the problems of such scarcity, and also the imagination and commitment to bring new techniques to bear.”

WorkStack follows a series of timber buildings for dRMM across multiple sectors, through different structures and at differing scales. This project successfully demonstrates the viability of timber in an urban environment.

Backed by the GLA as an exemplar for industrial intensification, and a recipient of Good Growth Funding, WorkStack is designed to create a new class of high-density industrial buildings which can be integrated within mixed-use development across cities.

For more information visit: www.drmmstudio.com Images: 01-02. WorkStack has been designed using CLT to provide an aesthetic and sustainable working environment. Courtesy dRMM Studio/Alex de Rijke

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SAVE THE DATE 16.04.2024

SHINING A SPOTLIGHT ON THE

‘BEST OF THE BEST’ IN STRUCTURAL TIMBER Structural timber is an exciting and fast-moving sector, with innovative and iconic structures changing the way we look at design. The Structural Timber Conference showcases the best of the best within the sector. Booking your place as an exhibitor positions your brand alongside the companies driving the future of timber technology and construction.

To become a sponsor or exhibitor, simply contact Jessica Holland on 01743 290044 or email jessica.holland@radar-communications.co.uk

WWW.STRUCTURALTIMBERCONFERENCE.CO.UK

STRUCTURAL TIMBER

MASS TIMBER LESSONS

Officially opened in June and operated by the University of Strathclyde, the new £11.8million National Manufacturing Institute Scotland (NMIS) is winning many plaudits for its sustainable mass timber building.

2023 WINNER

1 Sitting at the heart of the new Advanced Manufacturing Innovation District Scotland (AMIDS), and a partnership between the University, the Advanced Forming Research Centre, High Value Manufacturing Catapult, Skills Development Scotland and Scottish Enterprise, NMIS is housed within an architecturally striking and advanced two-storey structure where engineered timber is a key element to a hybrid design, optimising space and the beauty of the materials employed.

The materials and layout of the skills centre reflect the facility’s pillars of collaboration, flexibility and innovation, creating a unique identity that is both carbon-neutral and optimised for productivity.

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At more than 18,288sq m, the space accommodates the personnel and equipment needed for the programme and houses state-ofthe-art engineering equipment. The building features PEFC certified cross laminated timber (CLT) roof panels manufactured and supplied by Stora Enso, engineered and installed by Stora Enso’s partner B&K Structures.

The diagonal PEFC certified spruce glulam columns and extensive diagrid roof define the building’s striking appearance.

Glulam and carbon savings The glulam structure is both visible externally and internally and provides

a wide column-free space maximising flexibility and the potential for reconfiguration. The prefabricated diagrid structure and panelised CLT roof were assembled on-site, with bespoke CLT rooflight frames formed offsite to increase efficiency and accuracy. Framing the view into the facility, the glulam structure creates an architectural statement for the project, exemplifying NMIS’ values of innovation and sustainability.

The new ‘energy carbon neutral in operation’ facility will create an open and collaborative environment, that supports healthy working, fosters collaboration and promotes sustainability.

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STRUCTURAL TIMBER

2 Main contractor Morrison Construction worked closely with B&K Structures and supply chain partners Stora Enso and Rubner to deliver a diagrid style roof structure together with the diagonal glulam columns which define the building’s striking appearance.

The development exemplifies the University’s vision and values and innovates in all that it does. Led by the University’s design guides, which focus on whole building lifecycle, and underpinned by using sustainable, long-life and robust materials, the design is unique. A range of climate mitigation and adaptation solutions, including rainwater harvesting, SUDS and a green roof encourage biodiversity.

Window on the world Highly visible externally and internally, NMIS’s unique structural identity offers an 18 x 80m column-free space, maximising flexibility and the potential for reconfiguration. Visible on the skyline, the 32m x 12m ‘window to the world’ provides a view into the facility, framed by the dramatic glulam structure that springs above the office and collaborative spaces. Promoting sustainable and recycled materials, design processes reviewed options to ensure optimum energy efficiency over the lifecycle of NMIS and its components.

The Skills Academy seeks to create a high-quality, healthy workplace maximising natural daylight, with internal tree planting, and a bespoke internal green wall. Central to the design is the exposed timber glulam frame and CLT roof which supports the facility’s pillars of collaboration, innovation and flexibility. Achieving a BREEAM Outstanding rating, it exemplifies the sustainable goals of

3 the University, delivering an iconic identity for this world-leading facility.

Prioritising ‘fabric first’ passive principles, low U-values and energy efficiency, the building has quickly become a landmark piece of sustainable architecture. Professor Sir Jim McDonald, Principal & ViceChancellor of the University of Strathclyde, & Chair of NMIS Board said: “This flagship facility – which has sustainability at its heart – is a unique part of Scotland’s manufacturing innovation ecosystem. It will play a leading role in developing advanced

manufacturing, industry 4.0 capability and cross-sectoral research and innovation activity in Scotland, the UK and beyond.”

For more information visit: www.hlmarchitects.com www.bkstructures.co.uk www.storaenso.com/en www.engenuiti.com Images: 01-03. NMIS is a multi-award-winning example of sustainable, energy efficient, low carbon timber construction and was the Offsite Awards 2023 Winner of Winners.

Courtesy HLM Architects

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ADVERTORIAL

MOVING TO MORE TIMBER

According to the NHBC, timber frame now accounts for 28% of new housing starts in the UK and, according to research carried out by MEDITE SMARTPLY in 2023, the growth in the use of offsite building methods is set to continue, with systems based on timber being the number one choice.

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This recent research surveyed SME housebuilders, a group that has traditionally been reluctant to engage with offsite because of perceived cost and practical issues. Right now, 51% of those housebuilders are using offsite systems and this is a recent trend.

The average length of time that the companies have been using offsite systems is just three years.

innovation and product development is resulting in a number of efficient new options for the offsite sector, and manufacturer MEDITE SMARTPLY has been quick to expand its product range and develop performance-led solutions.

The trend is set to continue. Of those companies not currently using offsite systems, the majority are planning to do so and generally anticipate that they will turn to offsite within the next two years. Perhaps not surprisingly, the housebuilders cite a changing perception of offsite methods in the housebuyer audience. They point to a much more positive perception of offsite methods amongst homeowners and buyers of new homes.

The volatile nature of materials costs will play into this receptive market as the number one hesitation around adopting offsite methods has historically been cost. That situation is changed too as the majority of respondents see that it would cost the same – or even less – to build with offsite than their current building method. This is, of course, great news for the timber industry where

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Standard SMARTPLY OSB is perfect for structural panels or for use in structural Insulated panels (SIPS) while SMARTPLY ULTIMA OSB/4 has greater strength and has been developed especially for the offsite industry.

Great loadbearing capacity, moisture resistance and rigidity provide a high-quality structural solution for housebuilding.

Designers of high-performance homes requiring particularly strong performance in airtightness (such as Passivhaus designs) can now turn to SMARTPLY PROPASSIV and SMARTPLY SURE STEP to achieve the required results. Both these options are certified airtight and can be used together to form an opaque envelope for a structure. SMARTPLY PROPASSIV is an airtight structural OSB/3 panel with integrated air and vapour control.

It’s used for walls and ceilings with SMARTPLY SURE STEP providing similar levels of airtight performance for floors and decking.

MEDITE SMARTPLY was also early to the market with its comprehensive cradle-to-gate lifecycle carbon calculations, allowing specifiers to understand the low embodied carbon of its composite board products. No wonder that 65% of respondents in the housebuilder research reported that they thought modular building methods would help in the drive to reach net zero carbon.

Clearly the housebuilding market is receptive to the concept of timberbased offsite systems and increasingly, government incentives are providing even more encouragement. The Environmental Audit Committee (EAC), for example, has specifically recommended the increased use of wood in construction to help achieve the UK target of net zero carbon by 2050.

With low embodied carbon, sustainable manufacturing and costeffective systems readily available, timber-based offsite building systems seem set to become an ever more popular choice for building specifiers. Increased government support for these systems is helping to drive a transformative shift towards sustainable, efficient, and cost-effective construction methods, aligning with the UK’s target of achieving net-zero carbon by 2050.

For more information visit: www.mdfosb.com

Images: 01-02. Timber offsite systems play an important part in achieving net zero targets

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

STRUCTURAL TIMBER

NEW CONCEPTS IN SUSTAINABILITY

A mass timber solution helped Aldi Stores create a new retail outlet in Leamington Spa and act as an example of how future retail developments can be made truly sustainable.

2023 WINNER

1 The new Leamington Spa store is an explorative concept by Aldi Stores Ltd and the design team. They looked at the whole life carbon impact of the building from the outset, resulting in a project that ‘consumes less whilst contributing more’.

The Leamington Spa project reduces the embodied carbon by two thirds compared to similar ‘typical’ retail developments, with materials removed and reduced where possible.

Remaining materials are replaced with sustainable (whole life) alternatives where practical, and on-site renewable energy being harnessed before offsetting is considered.

Passive design solutions and plant efficiency improvements helped reduce the operational energy demand significantly, with the remaining energy demand offset through the substantial on-site renewable energy generation via the solar PV array. The vast majority of the solar panels are recycled from decommissioned stores, reducing the overall embodied carbon further.

Ongoing monitoring and resultant improvements to commissioning and operation will ensure that optimal energy performance of the store is achieved.

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The primary and secondary structural elements of the store are formed from cross laminated timber (CLT) and glulam. The feature ‘sawtooth roof’ uses a glulam truss to provide a clear span in the retail space with no interruption from columns or cross bracing within the North-light windows. The outer walls of the retail envelope are formed of CLT panels with the roof structure tied into it. The warehouse and ancillary spaces are formed of CLT panels acting as the structural element for the glulam beams that support the CLT roof panels. The CLT and glulam frame were produced offsite with all openings and recess pre-formed to assist with reducing the overall build programme once on-site. This required effective co-ordination between the architect (Stoas Architects), MEP, structural and specialist contractor to ensure all requirements were captured prior to manufacture.

The mass timber frame was a significant contributor to the store lowering its embodied carbon total to approximately 33% of a comparable retail development. Paired with the CLT and glulam frame was the introduction of wood fibre insulation, resulting in a thermally efficient envelope that can maintain a stable internal temperature much easier, which in turn allows

the operational energy demand to heat and cool the building to be significantly reduced.

The Leamington project has sustainability embedded in its core, with the client engaging the entire design team from the outset to develop a low carbon store, demonstrating how sustainable retail developments can be with innovative thinking. The clients brief from the outset was to deliver a low carbon building that was no more onerous to build than a typical retail development – the use of CLT and glulam for the structural solution, combined with offsite manufacturing technologies has seen happen and has provided a hugely attractive, healthy and sustainable building for the client, staff and shoppers.

For more information visit: www.stoasarchitects.com Images: 01. The new Aldi store shows how offsite thinking can deliver a striking, sustainable shopping environment. Courtesy Stoas Architects

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CASE STUDY

PRODUCT INNOVATION

UPS & DOWNS OF DESIGN The Ideal Lifts Frame System speeds up the construction programme by reducing reliance on skilled construction labour on-site and the use of standard shaft walls/panels without additional fixings. The Frame System includes all steel work, all lifting beams and pit ladders negating the need for scaffolding or the building in of specialist inserts within each wall and entrance and enables clients to provide a much-simplified lift shaft which is designed for offsite manufacture, with fire lining that can be completed prior to site assembly, with no on-site cutting and patching required. It also requires no landing rebates, simplifying construction on and offsite and maintaining full fire integrity.

1 Ideal Lifts were selected early in the design stage as the lift providers for TOG’s Black & White Building and showed how lift frame systems play an integral – and unsung – role in buildings utilising offsite methods.

that negates the need for traditional concrete lift shaft construction.

With nearly two decades of specialist experience and knowledge in the design and installation of passenger lifts for timber construction, Ideal Lifts were able to offer a unique solution with its Ideal Lifts Frame System – the system not only allows for typical vertical settlement but also the additional challenge of lateral movement, that comes with engineered timber.

Smarter than traditional construction, its unique design ensures that only a standard lift shaft is required. The frame system is designed, as standard, to allow for vertical building movement associated with natural timber. With the additional challenge of potential for 10-15mm lateral movement, the Frame System V6 design and construction were enhanced using adjustable frame abutments to enable the lift and lift doors to match any lateral building movement. This ensured that both passenger lifts and its Frame V6 remained in service during the building fabric movement period.

Ideal Lifts – the UK’s industry leader in installing lifts in timber buildings – was approached specialist due to a potential lateral shaft movement of up to 10-15mm. A solution had to be engineered to avoid the lifts going out of service due to inaccurate landing door alignment with the lift car. The Ideal Lifts Frame System is an innovative stand-alone structure

This is an issue experienced by other non-specialist lift contractors, that can make the lifts inoperable, unreliable, and requiring major remedial works. The Frame System is not only designed for timber buildings but for all modern methods of construction (MMC) including the increasing use of modular, light gauge steel and precast concrete construction.

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The Frame System is not only designed for timber buildings but for all modern methods of construction (MMC) including the increasing use of modular, light gauge steel and precast concrete construction.

Many lift providers issue standard drawings for the lift installation irrespective of the method of construction. Standard practice requires building manufacturers to adapt their standard design, manufacture, and installation to suit bespoke passenger lift requirements.

Ideal Lifts provide their clients with detailed site-specific construction works information (in CAD/BIM) to allow them to provide a simple nonload bearing lift shaft to interface with its frame system. The frame mounted passenger lift installation requires only standard walls or panels in timber frame, light gauge steel (LGS), modular and precast concrete to enable an efficient repeatable construction process.

For more information visit: www.ideallifts.com Images: 01. The Ideal Lifts Frame System speeds up the construction programme and is suitable for all offsite systems including timber, modular, light gauge steel and precast concrete.

Courtesy Ideal Lifts

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LIGHT STEEL FRAME

PUTTING SAFETY FIRST

Claimed to be the biggest change in over 40 years, the new Building Safety Act came into force with surprisingly little fanfare. To understand it more, the Light Steel Frame Association (LSFA) recently hosted a debate on the implications of this new safety legislation. we were expecting. However, the light steel frame manufacturing sector is well prepared, with checks and balances in place.”

1 The significance of this legislation was not lost on the LSFA which hosted a special roundtable event to debate the implications of the secondary legislation. A select invited group of legal professionals, construction consultants and light steel framing experts gathered in Birmingham for a lively discussion around the implications of the Act and the challenges involved.

Building a safer future Coming in the wake of the Hackitt Review and receiving Royal Assent in April 2022, the Building Safety Act covers a raft of changes introducing new duties for the management of fire and safety in high-rise residential buildings. The overhaul of regulations will require building owners to demonstrate safety at each of three new ‘gateways’ – planning and design, construction and occupation. The Act also has wider implications across all construction sectors.

The Building Safety Regulator based within the Health and Safety Executive, became operational from 1 April 2023 and the principal accountable person has been required to register high-rise

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residential buildings from that date.

On 1 October 2023, the secondary legislation needed to support the practical implementation of the Building Safety Act came into force.

The Building Safety Regulator will now monitor the construction industry and will be able to impose fines, order alterations or the removal of noncompliant work and has the power to prosecute individuals of corporate bodies.

Imperative for change Roundtable facilitator, Darren Richards, kicked off proceedings, asking – is the industry prepared for the new era?

“Designers, contractors and clients have a lot of work to do to get across the detail,” responded Tim Sims, Partner at Rider Levett Bucknall and lead of the Midlands Building Safety Fire Team. “We are ensuring we have the right competencies in place to advise our construction clients as the levels of enquiries increase.”

Andrew Way, Associate Director at the Steel Construction Institute (SCI) also expressed concern: “The lack of technical engineering enquiries we are receiving is certainly not at the levels

Collaborative action Roundtable debates can expose a divergence of opinions but throughout the two-hour discussion, there was consensus around the table. Universally the light steel frame manufacturers, engineers, and technology leads, welcomed the legislation.

“There is a particular focus on record keeping, meeting the requirements of a ‘golden thread’ of information, documenting every construction project,” said Matthew Grant, Head of Technical Development at Intrastack, part of Saint Gobain. “This is a particular strength of Intrastack and the digital savvy light steel frame sector.

We are well prepared.”

Ben Towe, Group Managing Director at Hadley Group added. “This is seen as a positive step forward which will mark a differentiation between manufacturers with and without test data. This legislation will reinforce the importance of being able to independently verify a systems’ performance in relation to building safety.”

It was proposed that the LSFA set up a working group to engage directly with the Building Safety Regulator to set a high bar and ensure that the light steel frame sector is at the forefront of implementation of new technology for traceability, design information management and robust construction details with validated performance.

“We should use the opportunities presented by the Building Safety Act as a catalyst for collaboration,” said

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LIGHT STEEL FRAME OCTOBER 2023

BUILDING SAFETY BULLETIN Building safety is a key concern of the Light Steel Frame Association (LSFA), our members and end-clients. Following the introduction of the Building Safety Act in 2022 and the secondary legislation which came into force on 01 October 2023, this bulletin has been developed to provide insight and signpost relevant information.

BUILDING A SAFER FUTURE

With far reaching consequences, on 14 June 2017 a high-rise fire broke out at Grenfell Tower in North Kensington, West London – one of the UK’s most devastating modern disasters. Over the course of Phases 1 and 2, the Grenfell Tower public inquiry disclosed over 320,000 documents to core participants, received over 1,600 witness statements and held more than 300 public hearings. The inquiry has concluded, and the panel is working on the final report.

Image courtesy of Sigmat

The government also commissioned an independent review of building regulations and fire safety. In May 2018, ‘Building a Safer Future’ by Dame Judith Hackitt was published. This review made recommendations, with many now passing through to legislation.

2 Nik Teagle, Joint Managing Director at Frameclad. “By working together under the umbrella of the LSFA, we can achieve common goals for the good of the construction industry and building safety.”

More stringent regime It has been unclear until now how the government would put the legal requirements within the Building Safety Act into effect, however this new legislation is intended to help ensure responsible parties operate within the law. “This legislation addresses key safety issues which should never have arisen but came sharply into focus as a result of the Grenfell tragedy,” said Farah Bandali, Legal Director, Shakespeare Martineau. “The Act was a reaction to the lessons learned and now the construction industry needs to keep pace with the legislation. It does not seem that this will be easy, or straightforward, as there appears to be a lack of standardisation of processes, but we are still hopeful that this is an opportunity which will result in longterm change for the good.”

MORE INFORMATION: www.gov.uk/government/publications/independent-review-of-building-regulations-and-fire-safety-final-report

WWW.LSF-ASSOCIATION.CO.UK

“The building safety legislation is intended to drive a cultural sea change,” added Victoria Ball, Partner, Trowers & Hamlins. “This is not going to be a tick box exercise for the industry. Construction professionals will need to embrace significant behavioural changes and the sector will be forced to adopt a different approach. The biggest challenge is around gateway three, right at the end of the project. Structures cannot be legally occupied until they have been through the building safety process, therefore, we must consider how the new completion and handover processes will play out. What is the likely impact on programme and occupation timescales? Collaboration in the industry is key to assist contractors to get smoothly through the gateway process and provide ‘golden thread’ details to meet building safety requirements.”

To download the Building Safety Guide, go to the LSFA information library at: www.lsf-association.co.uk

The LSFA would like to thank all roundtable participants for their valued input. A longer version of this discussion will be available in the next issue of Light Steel Framing Magazine: Darren Richards (facilitator) - Managing Director, Cogent Consulting, Andrew Way - Associate Director, SCI, Ben Towe - Group Managing Director, Hadley Group, Farah Bandali - Legal Director, Shakespeare Martineau, Matthew Grant Head of Technical, Development & Sales Support, Intrastack part of Saint Gobain, Michael Rowell - Engineering Manager, Fusion Steel Framing, Nik Teagle - Joint Managing Director, Frameclad, Tim Sims - Partner, Rider Levett Bucknall and Midlands Building Safety Fire Team Lead, Victoria Ball - Partner, Trowers & Hamlins and Birmingham Project and Construction Lead.

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NEW CHAIR AT LSFA Ben Towe, Group Managing Director, Hadley Group has been announced as the new Chair of the LSFA, taking over from Mike Fairey, who will stand down at the end of 2023. “It has been an interesting and extremely rewarding few years. I am so proud to have been involved in the formation and launch of the LSFA,” said Mike Fairey. “From a standing start the association has gathered momentum and with the rise in specification of light steel framing systems, we have grown in stature and influence.”

Ben Towe will take over the role in January 2024 with Mike Fairey remaining as Deputy Chair throughout the transitional term.

“The Association has some big challenges to address on behalf of our members over the next 12 months,” said Ben Towe. “As the construction industry grapples with the new Building Safety Act and legislation, my priority as Chair is to help our members get across the detail. Without doubt the new safety legislation plays to the strengths of light steel frame and we must help our members grasp the opportunities which are coming our way.

“We must also continue our campaign to raise awareness of the sustainability benefits of light gauge steel. Circular construction is rising up the environmental agenda and as the only building material that can truly be reused or recycled for the same or a similar purpose – steel is supporting construction by enabling clients to achieve safety legislation and sustainability requirements. And then there’s promoting the innovation in our sector – so there’s a lot to do.”

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

SCI Tedds Modules Light Gauge Steel Member Designer SCI has released the next module in our range of specialist SCI Tedds modules. This, and other modules in the range, complement and extend the capability of the widely recognised Tekla Tedds software.

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LIGHT STEEL FRAME

IN-HOUSE EXPERTISE THE KEY DRIVING FORCE

As a BOPAS-accredited light steel frame specialist, Frameclad’s advanced offsite manufacturing infrastructure is underpinned by customised digital technology. But as Joint Managing Director Nik Teagle says, the firm’s in-house capabilities are the driving force behind their success.

1 Don’t get me wrong, manufacturing and digital construction technology is massively important but with Frameclad, our strength lies in our people and the technical know-how within the team. From standard infill systems and off-the-shelf sections to vast medium rise bespoke light steel loadbearing developments – every project gets the same exceptional quality as standard, but it is our unrivalled customer service that sets us apart.

Transitioning from a merchant to a light steel manufacturer more than 15 years ago, we operate from two adjacent factories in Kingswinford with a combined area of 50,000sq ft of factory and office space. Substantial investment in six cold roll-forming machines, supported by customised Tekla software, produces one of

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2 the largest ranges of steel sections available in the UK today from a single manufacturer. But it’s our investment in in-house expertise that drives our business forward and keeps us ahead of the curve.

Design and Consultancy Solutions In spring 2022, Frameclad acquired Design and Consultancy Solutions (DACS) and has a 12-strong team of designers and engineers based in our office in Teesside. Providing cost estimates within 10 days and detailed designs within one week, our inhouse team can make swift decisions and go that extra mile to meet rapid turnaround times.

Design for Manufacture and Assembly (DfMA) is at the very centre of every offsite project, so we believe having total control over the manufacture

and design elements is essential. Our design and engineering team, work in total synergy with our client’s architects to ensure a cost effective, safe and sustainable solution – that will not only be robust and reliable but is also practical to install. One project that demonstrates this, is the Chocolate Factory.

Pick and mix steel solutions The development in London’s Wood Green takes its name from the old Barratt & Co confectionery factory that once stood on the site. We are responsible for delivering the secondary structural framework, from design and engineering to fabrication and on-site delivery. Block E2 is being transformed into 71 apartments and nine duplex houses, with the structural steel frame now due for completion.

The Chocolate Factory development

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LIGHT STEEL FRAME

3 combines infill light steel for the building’s lower floors and panelised loadbearing frames to construct the top storey on the sixth floor, with only minimal requirement for structural reinforcement.

When it came to detailing the loadbearing frames of the top floor, the large panel sizes presented us with a challenge from a logistics point of view. We overcame this by carefully considering the size and weight of the individual frames and how these could be loaded onto lorries and transported to site safely.

This is where our investment in Tekla Structures software came in. With our in-house skills supported by digital technology, the design and

4 engineering team were able to identify the weights and centre of gravity for each component, carrying out checks and generating reports. This was a massive help in ensuring we didn’t encounter any roadblocks further down the line, with potential problems being identified at an early stage.

Building Information Modelling (BIM) offers the ability to check, verify and compare information in a digital environment to ensure it is correct, before progressing to fabrication. For the light steel frames on the ground level to fifth floor, a clear benefit of the constructible modelling software was the ability to break down the individual steelwork using the user-defined attributes. This meant that we were able to automatically sort the steel by

FRAMECLAD Frameclad supply a complete range of loadbearing and non-loadbearing light steel framing systems and sections to the construction industry across the UK. Backed by BOPAS Accreditation to design at full scope, NHBC SCI, Infill and CE Certification, Frameclad has also invested in a growing suite of fire test and performance data to offer assurances to main contractors, architects, engineers and public sector clients.

With a can-do attitude and in-depth technical know-how, they are keen, fiercely competitive and are considered trailblazers within the light steel sector.

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phase, floor and zone, with the ability to easily filter and sort the information needed at a specific time to generate fabrication reports, and efficiently phase manufacture and delivery of the steel framing solutions.

Once fabricated, each piece of steel also had a unique code stamped on it detailing the specific zone, floor, profile size and steel length. The site team could therefore easily identify the location for each piece of steel.

All of this made for quicker and more organised fabrication, delivery and assembly processes and facilitating just-in time deliveries.

The framework for Block E2 is due for completion and is the result of another successful collaboration with up-andcoming contractor Formation Design & Build Ltd. The Chocolate Factory development as a whole is expected to be completed by early 2024.

Images: 01. Nik Teagle, Joint Managing Director, Frameclad 02-04. The Chocolate Factory combines infill light steel for the building’s lower floors and panelised loadbearing frames to construct the top storey on the sixth floor

NOVEMBER/DECEMBER 2023 | WWW.OFFSITEMAGAZINE.CO.UK

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LIGHT STEEL FRAME

A PARTNERSHIP DELIVERING INNOVATION & RESULTS

Fusion Steel Framing became part of The Hill Group in July 2022, with both parties aligned in their vision for high-quality housebuilding, MMC and sustainability. Mike Fairey, Managing Director of Fusion Steel Framing, picks out some recent successes.

1 Building on a shared foundation, our specialist teams have combined expertise and are collaborating on many development projects. Hill is a five-star housebuilder with an impressive industry track record, and we are delighted to be supporting them on-site in various ways.

Kew Bridge Rise in Brentford, West London, is a project we are particularly proud to collaborate on. Located within the heart of the Brentford regeneration area, this joint venture partnership between Hill and L&Q will deliver 441 new homes, including 50% affordable housing. We are excited to be deploying our innovative TRAXTM system as part of the project, a highly economical, non-load-bearing infill solution that enables us to create rapid dry building envelopes across various building types that use steel framing.

On a project like Kew Bridge Rise, the added value Fusion brings has significantly enhanced Hill’s construction approach, contributing to increased efficiency, improved quality, and notable reductions in waste and construction traffic. The TRAXTM innovative design streamlines the assembly of steel framing,

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drastically reducing the time required for construction. Our high-grade manufacturing facility in Northampton facilitates the production of TRAXTM with exceptional precision under controlled conditions, ensuring highquality components. In collaboration with Hill’s project team, the offsite fabrication minimises disruption and health and safety risks at the construction site while maximising the accuracy of components, resulting in faster installation. Collectively this process creates a more efficient and co-ordinated construction process that aligns with the partnership’s shared commitment to delivering a development of the highest quality.

At Ivy Lane in Oxford, we are using FusionXTM, a fully tested noncombustible load-bearing walling solution developed in response to Building Regulation changes. The project jointly led by Hill and housing provider A2Dominion will provide a new residential development at the John Radcliffe Hospital on behalf of Oxford University Hospitals NHS Foundation Trust (OUH). Designed to replace the Trust's former accommodation with seven new buildings, including 68 apartments and 57 shared accommodation units, each equipped with four or five bedrooms, this project will house over 340 key workers.

By working in close collaboration with Hill, understanding their objectives, and providing our input and recommendations on how best to utilise light gauge steel framing and MMC solutions, I believe both teams are continually advancing our capabilities and knowledge. This will certainly put us in good stead for the forthcoming project at the Fosters Estate in Hendon, in the London Borough of Barnet, where Hill is

working with Sage Homes to deliver 217 new affordable homes, including 75 extra-care homes, on behalf of Barnet Council. As one of our most technical projects, the development will involve creating a load-bearing system supplemented with over 77 tonnes of hot-rolled steel per block.

We are relishing the opportunity to contribute to delivering a more sustainable and efficient project, as experienced industry leaders in MMC, along with our extensive range of light gauge steel solutions.

I believe that by working in partnership with Hill, we have been able to improve our processes at Fusion and advance Hill’s capabilities within MMC. This has been achieved through collaborating on these key projects, as well as at other joint assignments. The learnings from each project go into our continuous research and development, resulting in faster innovation in producing new light gauge steel solutions and refining our existing product range.

Since the company’s foundation in 2000, Fusion has delivered more light steel residential structures than any other European producer and worked with some of the largest contractors and developers in the UK construction industry. I believe this latest chapter, now as part of The Hill Group, is set to be the most exciting chapter in our history yet driven by collaboration with our new partners.

For more information visit: www.fusionsteelframing.co.uk www.hill.co.uk Images: 01. Mike Fairey, Managing Director, Fusion Steel Framing

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GRAITEC ROUNDTABLE

CHALLENGES AND OPPORTUNITIES: DESIGN SOFTWARE IN AN ENVIRONMENTALLY CONSCIOUS WORLD Graitec – an Autodesk Platinum Partner and global developers of CAD/CAE software – recently invited offsite sector experts to a roundtable discussion surrounding the links between design software tools and the environmental impact of the structures we create.

1 Construction professionals at every level are increasingly involved with digital technology and how it helps them achieve the transformation in quality our built environment desperately needs. Offsite construction is also adopting digital tools and technology as an aid to further boost the huge benefits it offers clients and specifiers.

Operating at a global level, Graitec knows the vital importance that leveraging the power of technology plays in developing more sustainable

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and efficient builds. Representing Graitec, Rawad Assaf, Solution Technical Director, welcomed attendees and outlined the importance of conversations about software development between collaborators in the design software arena.

While contributing to a more sustainable future is a goal shared by everyone at the table, it quickly became clear that there was a much larger discussion to be had, looking not only at design software tools but also strategy, collaboration and overall

approach. All parties agreed that it is not just about having the right tools to do the job – but finding the perfect marriage between digital design and practical applications.

Understanding the landscape Patrick Hayes, Technical Director for IStructE, reflected on the changes in the offsite sector over the past few years. “Back in 2012, we were working on a project that required a carbon calculation, but there was no tool for it, so we had to make our own. This has really been the story of the industry

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

GRAITEC ROUNDTABLE

2 – we developed our own tool, and other companies are making and using their own. The question has become how do we find a common standard?

18 months ago, the focus was on operational carbon as an industry.

We have realised that as we make buildings more efficient, the challenge going forward will be embodied carbon. How are we sharing that data?”

The need to utilise data to refine and value-engineer more sophisticated sustainable modelling is something that Rory Bergin from HTA Design was keen to pick up on, following his experience of working on many projects with Vision and Tide. “Working with them we have done three studies now, which are all based on final data,” said Rory. “As a manufacturer they have fantastic final data, whereas within a traditional construction approach, it is much harder to get because actually no one is measuring the range, or the data is with a sub-contractor. There are gaps.”

When it comes to understanding the current landscape around digital software and the challenges posed to the industry – particularly around data sharing – Rawad Assaf suggests that the solution is in advancing building information modelling (BIM) to ensure continuity. “There is an issue in construction now with data continuity – how we ensure data will not be lost when moving from architect to engineers to the construction site. The answer is BIM, and we are trying our best to have a positive impact, looking at ways to ensure data continuity across all elements, going from scratch to the construction site and back for maintenance as well.”

Interoperability and integration Looking at the digital software market, it would be easy for the industry to accept the status quo, something Daniel Leech, CEO of Design 4 Structures, thinks is holding back interoperability. “The market expectation is that everything up to RIBA stage three is via Revit.

We take that data and apply it to a manufacturing level of detail before having to incorporate the IFC into Tekla. We then get interoperability issues between Revit and Tekla. The interoperability of both analysis and modelling software is a real challenge.

We would love to be able to develop that interoperability more.”

While interoperability does pose a challenge, Nicola Carniato, Technical Director for engineering consultants AKT II, was keen to point out that the vast scope of tools available also brings opportunities to produce more durable and circular structures. “There is an issue with software integration, but there is also an opportunity – the scope of tools means we can get the normal structural analysis, but also look at things from an efficiency perspective. With so much software, I talk with my colleagues and say – look, we have so many tools to check in – we do a side-by-side analysis, not only on our design but on the efficiency of the building.”

Collaboration between software developers is needed to avoid the inevitable proliferation of incompatible platforms. With so many companies creating bespoke solutions for universal challenges, a lack of interoperability is undoubtedly holding the industry back. “When we look at

the proliferation of tools, the thing that concerns me is where is the data for those tools coming from?” says Rory Bergin. “You can have as many tools as you like, but if they say different things about the same material, its a problem.

From a design point of view, we need to be confident that whatever tools we use are giving us the information and results that will stand up to scrutiny.

Things like carbon need to be based on a common platform.”

Ben Harper, Technical Manager, British Offsite, believes the obstacles for smaller software companies go beyond the monopolisation of the market by the big players. “You have all these big software companies that have the reach and money – it is difficult for a smaller company to try and create that interoperability.

You have got everyone wanting to build a unique building.

Interoperability becomes a struggle – because we are all trying to work with full-scale models, so your Revit, your IFCs, your central models, which is another bit of software again, is trying to do everything and talk to everything, which means you have all these companies out there trying to create software that does a myriad of things.”

With so many companies creating bespoke solutions for universal challenges, a lack of interoperability is undoubtedly holding the industry back.

A ’perfect storm’ Daniel Leech describes what he calls 'a perfect storm' across the construction

NOVEMBER/DECEMBER 2023 | WWW.OFFSITEMAGAZINE.CO.UK

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GRAITEC ROUNDTABLE

3 model from procurement to delivery.

“The reality is we have one massive player who set the standard – if we are not going to change the market structure, then the answer is to have a common platform. But if we do that, are manufacturers also coming together on a common platform?

We need to look at procurement and contracts because this interoperability challenge leads into a perfect storm where the whole industry has become so risk averse. To innovate and develop the software and create those tools that allow for interoperability, you have to take a monumental risk. Until we change the way that we procure and the way that we contract, and we make that more of a shared responsibility, there will be reluctance.”

Tackling the subject of incremental evolutions in technology, discussion around the table turned to structural engineering, sustainability and modelling. British Offsite has discovered that finding a system that can meet all requirements is a real challenge as Ben Harper explained: "Right now, we use Vertex – it works well for creating panels. It does the Howick outputs, it does the Randek outputs – that is a great. But the integration with that bit of software is not very good. That forces us into a position where one of the things we are considering now is – will we still be using Vertex in five years? Probably not. We are trying to find a solution that integrates everything.”

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Collaboration to achieve common platforms is something that Graitec is keen to develop. But how can it be achieved? “At Graitec, we are partners with Autodesk,” says Rawad Assaf.

“One of the largest partners in the world, and at the same time, we are editors. That is why we have many solutions – Simulate Solutions, which is for structural engineers, but we also have Create, Fabricate Solutions and Connect. We recently created a Connect solution to start collaborating in the cloud because, as everyone says, it is a matter of being able to collaborate. We have add-ons on Revit, Inventor, and other software regarding Autodesk and we are trying to work in the transversal direction to connect all these in an environment outside the Autodesk ecosystem. It is an interesting challenge.”

Sustainability and circularity The links between digital design software and creating sustainable structures also offers an opportunity to take a closer look at ‘design for deconstruction and disassembly’ at an early stage. Ben Harper added: “People talk about the Golden Thread and want a timeline of the products in a build. This is something we have been doing for six years. You can put a barcode on a panel, and I can tell you where the steel comes from, where the insulation comes from.” Rory Bergin agreed that the principle of enabling deconstruction and not forcing the demolition of a building was a crucial step forward in achieving more circular design. “If you can demonstrate that you can deconstruct the building into

its parts and then do something with them, you can show a pathway to reuse, reconstruction or recycling.”

There is no doubt that circular design is starting to become a common element in design briefs. Developers are thinking more about the future use of buildings and how utilising design software can account for potential reuse. Robert Mills, Associate Director, Whitby Wood has seen an increase in the drive for circular economy design with their clients. However, is not without its own challenges. “One of the difficult things about circular design is finding the delicate balance between adapting and designing – between what you are putting into the building now, in terms of materials, and how those might be used in the future. Because you don't want to over-design and end up adding more embodied carbon at this stage when it may never get adapted in the future.

The main thing is understanding how the building was erected and documenting that because it may have to be demounted in the long-term future.”

While demand for a more circular approach is increasing, there is still a way to go in terms of finding the balance between flexibility and meeting the operational requirements of the building, particularly when looking at the wide scope of materials and approaches used.

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GRAITEC ROUNDTABLE “Firstly, when you take a step back and look at behavioural changes – what drives them? One is aspiration. There are aspirations for clients driving the circular economy and you can see that particularly on the steelwork side. We want to reuse steelwork. The reality is that most of the industry is driven by legislation. Circular business will get driven by legislation because, when you look at the mission zero report, that's all based around circular economy and minimising waste. But there isn't a one size fits all solution to the question of circular design. You've got to be realistic. The problem arises when the building is just not adaptable at all. What if I want to create a hole in it? Can I do it? There are levels of flexibility which tie themselves to a structural system, and that's what you need to look at.”

With no ‘one size fits all’ solution to circular economy design, Rory Bergin spoke about the need for better leadership, legislation and guidance, the current lack of which may exacerbate the proliferation of different tools, as different markets seek to meet their own individual circular targets. “It is going to be a problem in the future. I think the leadership is missing, leadership at the top of the of the chain. Construction is so diverse and splintered into so many small organisations that you need to see leadership. I don't really think the sector has it and it is not coming from government right now. We might see a change, but I prefer in some ways if the industry led itself. We must take control of ourselves and get the guidance in place. What recycled content should we be aiming at? What is achievable?

What testing standards should we be using? I think within the industry we need somebody to look at the whole thing holistically.”

4 CONTRIBUTORS

Facilitator Darren Richards

Rawad Assaf

Rory Bergin

Nicola Carniato

Solution Technical Director, Graitec

Partner, Sustainable Futures, HTA Design

Technical Director, AKT II

Ben Harper

Patrick Hayes

Daniel Leech

Robert Mills

Technical Manager, British Offsite

Technical Director, IStructE

CEO, Design4Structures Associate Director, Whitby Wood

Director, Cogent Consulting

When it comes to improving the environmental credentials of any build, Nicola Carniato favours the holistic approach. “This is where I see another opportunity – we are talking about BIM co-ordinators. You now see people thinking more about investment in that particular sector to try to realign the models together. I would rather create opportunities in design softwarewise, so it eliminates that risk. We have to look at operational energy, for example, to choose the right materials.”

and there are lessons to take from other industries about finding that perfect marriage between the two.

“I think it has come full circle back to the first point about interoperability,” says Dan. “The software and technology are so good and advanced.

Young people pick up the software quickly. The problem is they still need the input of experience. Even though the software says it can do X, we know in reality it will do Y. I think there could be a lot of cross-pollination from industries like the gaming industry, but we have got to make our industry more attractive to those people. Look at the automotive industry – they have taken the time and the effort to do it right. It feels to me like the whole construction industry needs to slow down and take stock.”

Daniel Leech believes that there needs to be better integration between software use and practical application,

One of the key concerns across all aspects of the offsite sector is interoperability and this was a

common theme running through much of the roundtable discussion. The deeper use of software and availability of digital tools that enable better and clear options for design teams is literally at our fingertips. It is through wider collaborative efforts between all those involved to find more effective ways to help the construction supply chain achieve their digital and built environment transformation goals.

Many thanks to Graitec for hosting the roundtable event and thanks to all participants for their time and contributions to the lively discussion.

For more information visit: www.graitec.com Images: 01-04. Courtesy Graitec

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PRECAST CONCRETE & DIGITAL TOOLS

DATA QUALITY & VISIBILITY

Precast concrete and DfMA plays a huge role in the construction of new prisons, and at HMP Millsike, these have been allied to a cuttingedge workflow and component tracking system that delivers huge efficiencies.

2023 WINNER

1 As part of the Ministry of Justice (MoJ) drive to increase speed of delivery while minimising costs, Kier is part of a team using platform design to construct the £400million HMP Millsike, one of four new prisons that form the New Prisons Programme.

Set to provide almost 1,500 additional prison places, the project will use 14,550 precast concrete components and circa 90,000 subcomponents manufactured across nine factories.

The pioneering new digital initiative is enabling significant reduction in project costs and time despite the use of multiple components and a complex supply chain. By combining new and existing technologies into a single streamlined process, it is helping to reduce workhours required to check multiple sites, improve quality and minimise risk of errors using a single system – and reduce

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time on programme between design, manufacture, logistics, sign-off and installation.

As lead contractor, Kier worked closely with MoJ, PCE and the Ynomia team to develop a bespoke solution for HMP Millsike. The process, supported by software provider Ynomia, provides unprecedented realtime visibility of offsite components, allowing for faster, greener, and more efficient delivery including: time and cost savings, requiring significantly fewer staff to manage component interfaces, reducing carbon footprint by removing multiple factory visits and critically minimising risk through certainty of quality and delivery.

Ynomia uses Bluetooth Low Energy (BLE) tags on components that trigger milestones as they move past beacons.

These make direct links to data sources

already in use, such as Viewpoint, that can be accessed via a mobile device.

Combining these elements provides a 360 degrees ‘live’ perspective, tracking components in real time to make decisions quicker and more efficient.

Traditionally the precast process is managed in various non-integrated systems. This can lead to poor visibility and increased potential for human error, resulting in reduced quality and an increase in programme duration. By providing an automated, standardised way to track components from design through to installation, Kier can efficiently monitor quality and progress across multiple factories simultaneously. The ‘live’ element and integration of new and existing technologies sets it apart from techniques used elsewhere in the industry. The ‘digital construction twin’, enabled by Ynomia, provides full

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PRECAST CONCRETE & DIGITAL TOOLS visibility of component journeys across multiple locations, where the whole team can access to create a single, datacentric ‘source of truth’ that can be used throughout the whole offsite supply chain. To make sure Ynomia was implemented successfully up and down the supply chain, a new training programme led by Kier, PCE and the Ynomia teams was introduced.

HMP Millsike, as part of the MoJ’s New Prisons Programme, has a high profile with a wide-reaching audience, enabling everyone involved to showcase the benefits of Ynomia across the construction industry.

Kier is taking this template and not only applying it to future projects for advanced offsite, MEP and modularised unit management, but also sharing this tool with its supply chain members.

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For more information visit: www.kier.co.uk www.pceltd.co.uk www.ynomia.io Images: 01-02. The Ynomia component tracking system is streamlining the understanding of a complex prison project supply chain.

Courtesy Kier 03. PCE team on-site at HMP Millsike.

Courtesy PCE Ltd

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MODEL FOR PRISON CHANGE HMP Millsike will be 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.

PCE Ltd has been appointed by Kier as its superstructure and façade delivery partner, with the MoJ project having an overall contract value of £400million. This 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.

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.

“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 newlybuilt 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.

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PRECAST CONCRETE

THE NEW SHERRIFF IN TOWN

The Sherriff’s Gate development in Worcester showcases why using precast concrete and MMC combine to provide project delivery with speed and precision. MPA UK Concrete gave us an overview of the scheme.

Safe Systems of work were drawn up which included a detailed lifting plan, crane positions, traffic movement, truck positions, and access and egress points. On other projects, a day's deliveries would normally comprise precast walls, followed by another day for floors. But the project's swift nature mandated wall fittings in the morning and floor placements by the afternoon.

This delivery plan was tight, especially with loads arriving from Ireland and Barry in Wales.

Precast elements supplied included: hollowcore floors, 8,800sq m (200mm) and 750sq m (250mm), 9,400sq m of solid walls and 30 flights of stairs – widths between 1.1m-1.3m.

1 O’Reilly Precast’s meticulous planning and faultless deployment of the concrete frame meant that the project was shortlisted for ‘Best Use of Concrete Technology’ at the 2023 Offsite Awards.

The goal of the £150million project is to repurpose 900,000sq ft of industrial land, turning it into a mixed-use community development which will be transformative for the area. In addition to the residential blocks completed in phase one, the project will also provide other housing options, a hotel, gym, multi-storey car park, food and beverage outlets, a multiscreen cinema and a ten-pin bowling facility.

The whole scheme will generate economic growth in Worcester and greatly enhance the appeal of the Shrub Hill area, creating a vibrant hub for residents and visitors.

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MPA Precast member, O’Reilly Precast, in partnership with the Elliot Group began work on the project in July 2022 and the entire scheme it is set for completion within three years. The first two blocks, John Gregory Court (105 units) and Wilson Roberts Court (108 units) were completed in just over 100 days – an ambitious timeframe achieved using precast concrete.

This phase of the development was completed not only on-time but on-budget too, all despite numerous logistical challenges for the precast manufacturer. Its central Worcester location meant that, co-ordination with the installation team was vital. Up to 14 articulated truck deliveries were co-ordinated daily to service the two installation teams.

The success of precast construction at Sherriff’s Gate lay not just in the rapid site erection but in half a year's rigorous planning before the on-site kick-off. Detailed design team discussions with Elliott’s determined structural and scheme specifics. Subsequent alignment with Elliott’s key personnel ensured the scheme was delivered on-time and within budget.

“Working with O'Reilly Precast allowed us to stay ahead of a very tight schedule on the Sherriff’s Gate project, says Tom Powell, Project Manager, North and Midlands, Elliott Group.

“Their full frame precast solution was spot-on for efficiency, meeting our needs for modern construction methods and BIM compliance. The co-ordination between their team, our management, and the subcontractors was key to the smooth delivery of materials, especially in the logistics-

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PRECAST CONCRETE

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heavy environment of a city centre site.

O'Reilly’s ability to manage multiple deliveries each day made a real difference in keeping us on-track.”

Close co-ordination with other construction partners such as NAB Flooring Ltd, the screeding contractor, permitted ceaseless precast structure erection, devoid of delays due to environmental factors, the type of which can plague the erection of lightweight modular structures, such as high winds.

The Sheriff's Gate project exemplifies the importance of precision, collaboration, and meticulous planning. O'Reilly Precast's commitment to detail and coordination within the supply chain ensured the delivery of a complex project within a challenging timeframe. The success achieved at Sheriff's Gate serves as a testament to the capabilities of modern offsite construction methods.

This year the ‘Best Use of Concrete Technology’ category in the Offsite Awards has once again shown why the material should be the ‘go to’ choice for offsite construction. The winner the was the eye-catching 14-storey Assembly C project, delivered by PCE using its HybriDfMA Frame System, with elements manufactured by MPA Precast members Creagh Concrete Products and Explore Manufacturing.

The structure exemplified the beauty of an exposed concrete façade whilst also reducing project carbon emissions though reduced materials, linings and finishes. The real differential on projects like this being the impressive performance characteristics, material

4 standards and precise delivery techniques achievable through offsite solutions.

Elaine Toogood, Director of Architecture & Sustainable Design at the Concrete Centre and member of the judging panel was impressed by the showcase which the award provides.

“The Concrete Centre were delighted to be able to sponsor the ‘Best Use of Concrete Technology’ Offsite award again this year, and it was a pleasure and privilege to help judge the entries. This years’ shortlist, as ever, illustrate just some examples of excellent development taking place using precast concrete to offer even more efficient and lower whole life carbon solutions.”

The increased use of precast concrete in offsite construction can guard against a generation of lightweight modular building stock which lacks the longevity and inherent resilience of traditional construction practices.

Concrete is not only on the cutting edge of MMC but provides peace of mind for owners and occupiers with unrivalled fire safety and climate adaptation properties.

For more information visit: www.mpaprecast.org www.oreillyprecast.co.uk Images: 01-04. The Sheriff's Gate project exemplifies the importance of precision, collaboration and meticulous planning

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PASSIVE FIRE PROTECTION

SPEARHEADING SUPERIOR FIRE SAFETY

Building safety is a key concern for all those operating in the offsite and wider construction industry. To help focus minds further a key discussion area at Offsite Expo 2023 offered valuable insights surrounding fire regulations.

1 It has been a year of major changes and shifts in both regulations and approaches to ensuring structures achieve maximum performance and efficiency. But where are we right now, and what should the objectives be for the next twelve months?

Offsite Expo 2023 gave delegates a chance to hear more about some of the most relevant topics of conversations within the offsite industry and unsurprisingly, one of the most popular was that of fire safety, the recent changes to regulations and how the industry is adapting to meet the needs of a post-Grenfell construction landscape.

The fire protection masterclass session was chaired by Tom Mason, Director of Fire Safety Engineering at Kiwa Fire Safety Compliance, alongside David Fitzpatrick, who has previously served on the CIBSE board, Liam Blears, Head of Facades at FSi and Nichola Harrison, Assistant Director of Facilities, Fleet and H&S at Paradigm Housing Group.

The presentation touched on the recent changes affecting the offsite sector, including the second staircase ruling and evacuation lifts. There was

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also an overview of the amendments to the Building Safety Act 1984, including the new section defining a high-risk building. The Higher Risk Buildings Regulations came into effect in April 2023, with all qualifying buildings required to register before October. The information needed for registration included details of the fire protection strategy for the building as well as structural materials, roof and external walls, number of staircases and the fire and smoke control equipment used. It also laid out accountability when it comes to management of sites and developments.

Liam Blears, Business and Technical Development Manager for Facades at FSi was there to talk about the importance of onward planning and ensuring offsite construction techniques are compatible. Liam spoke about FSi's focus on cavity barriers, essential to the efficient operation of an open state system wherein the cavity barriers expand to compartmentalise airflow gaps behind the façade to delay the spread of flames and smoke around the outside of a building in the event of a fire.

Quality passive fire protection is vital to the safety and performance of all buildings, whether steel frame, timber or modular. FSi provided passive fire protection via the installation of cavity barriers in several modular buildings, including 101 George Street, one of the tallest modular buildings in the world. Liam said: “As specialists in this field, we are fully aware of the importance of excellence in installation to ensure that cavity barriers are fitted to their exact specifications and work effectively to seal the compartment and leave no gaps. This is life-critical in the event of a fire breaking out.

Ensuring correct specification and

installation is what makes the difference here. There’s absolutely no room for complacency in fire protection. It needs to be right.”

Offsite technology is well positioned to meet and exceed the changing construction landscape and fire safety changes come into effect. This is particularly the case when it comes to the early design and specification of a building, where potential risks can be identified and mitigated.

Liam went on to say: “Offsite construction is an area that supports best practice from the point of view of early planning, to allow cavity barriers to be sized correctly in advance and made available at the right time, as well as supporting on-site installation inspections as the development stages are carefully timed.”

When it comes to making buildings more fire-safe, the goal for the industry now must be best practice. The offsite industry is known for trailblazing more efficient ways of producing buildings –early-stage planning and fire-safe product development at specification stages will be instrumental in replicating standards across the board.

As plans to expand the government’s cladding safety scheme puts increased focus on the passive protection market, the attention of the industry must turn to improved transparency, collaboration and data sharing between suppliers, manufacturers and developers to ensure maximum safety for all building occupants and users.

For more information visit: www.fsiltd.com Images: 01. Liam Blears, Business and Technical Development Manager for Facades, FSi

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DEDICATED TO THE

DEVELOPMENT AND APPLICATION OF

OFFSITE MEP SYSTEMS NOV/DEC 2023 ISSUE ONE

PLUG AND PLAY OPTIONS STREAMLINING CRITICAL BUILDING SERVICES P82

P84

P92

APEX MODULAR SYSTEMS Providing modular wiring and mechanical sub-assemblies for the offsite sector

NG BAILEY Using MEP to deliver a safer, better, faster and greener future

VOLUMETRIC™ Kew Bridge Rise sees the latest in bathroom and MEP pod technology

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BUILDING ESSENTIALS

CONTENTS

Welcome to our special magazine section highlighting some recent projects and businesses operating within the mechanical, electrical and plumbing (MEP) space inside the offsite sector. All of whom let us know some of the reasons why this unheralded aspect of premanufacture should be grabbing more headlines.

Whilst offsite construction conjures up images of homes, schools, hospitals and all sorts of differing building typologies, the role of MEP services often get overlooked. These services are all-important parts of the buildings where we live, work and spend valuable time in. These building services are critical parts of everyday usage – we all use the bathroom and WC – and we all want to be in warm and energy efficient surroundings. The factory manufacture of these products and the way in which specifiers and engineers view them means that a renewed focus is required on the world of pipes, wiring and water systems.

Over the next few pages, we hear from several key businesses operating in the sector that offer up plenty of advice and a range of ways where prefabricated MEP systems and units can be installed. These lead to improved productivity and efficiency and critically can go a long way to prevent all kinds of installation errors that inevitably arise when done using traditional site-based habits.

OVERLEAF…

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APEX MODULAR SYSTEMS The opportunity to participate in the Seismic project proved the catalyst that would lead to the launch of a new M&E provider – Apex Modular Systems (AMS) – and a string of exciting new contracts.

NG BAILEY Scott Moran, Operations Manager for NG Bailey Offsite Manufacture, outlines how an ‘offsite first’ approach could help build a safer, better, faster and greener future for MEP.

CONTAINERISED & READY TO CONNECT IDS, part of M Group Services’ Water Division, was appointed to design and build a containerised process treatment plant by its client IXOM and used offsite manufacture to do it.

ENSURING PLUMBING QUALITY AT EVERY STAGE Offsite modular construction is playing a key role in shaping the industry’s future, but it requires a specific approach to design and material choices.

This is especially true for heating and plumbing systems. Paul Whittall, Business Development Manager for MMC at Uponor, explains more.

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IDEAL DRAINAGE SOLUTIONS

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RISING POWER WITH VOLUMETRIC™

Martyn Rowlands, Managing Director at Pipekit, is seeing demand for prefabricated drainage systems grow and is busy scaling up the business to cope.

Due for overall completion in 2026, Kew Bridge Rise is a major residential development on the site of a former Citroen garage in Brentford, West London and will feature the latest in bathroom and MEP pod technology.

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TOTALLY WIRED FOR OFFSITE

The opportunity to participate in the Seismic project proved the catalyst that would lead to the launch of a new M&E provider – Apex Modular Systems (AMS) – and a string of exciting new contracts.

Wiring Solutions (AWS) has proved to be a fertile environment in which to pioneer and perfect new products and solutions.

THE APEX MODULAR WIRING SYSTEM IS A UNIVERSAL SOLUTION SUITABLE FOR ALL BUILDING TYPES, COMPRISING PRE-WIRED AND PLUGGABLE DISTRIBUTION BOARDS, MASTER DISTRIBUTION BOXES (MDB’S) INTERCONNECTING CIRCUIT CABLES AND PRE-WIRED AND PLUGGABLE WIRING ACCESSORIES AND SECOND FIX (SECONDARY) DEVICES.

1 The Seismic development project, a two storey, six module volumetric building manufactured jointly by Algeco and McAvoy, was designed to showcase innovation within the offsite manufacturing sector. This was the driver behind the creation of specialist offsite M&E services provider AMS. A collaboration between industry innovators, the building included the installation of the Apex Modular Wiring system, separately at the Algeco and McAvoy facilities, coming together seamlessly when the six units were erected at the BRE site in Watford.

Encouraged by the opportunity this created, AMS was formed to provide both mechanical and electrical services for the offsite building sector in a progressive and innovative way.

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From the outset, the primary aim of AMS has been to provide a more efficient method of installing M&E services into offsite facilities - with a view to improving efficiency and driving productivity.

Demand within the construction sector (for offsite manufactured buildings) has never been stronger, prompting manufacturers to look for new ways to streamline their process to yield more output. Working closely with a number of key manufacturers within the offsite sector, AMS have invested time in understanding their products and processes, which has informed the development of solutions which drive efficiencies.

Additionally, the synergy between AMS and its colleagues at Apex

Offsite manufactured mechanical components comprise of standard solutions common to most building types and tailored solutions for specific applications. AMS, in collaboration with AWS and their clients, have developed mechanical riser modules for use within multi story buildings seen within single living accommodation (SLA) blocks and prison cell blocks, as well as horizontal corridor modules carrying the M&E services. Pre-manufactured mechanical sub-assemblies (MSAs) are used for toilet and wash hand basin installations, as well as a host of other plumbing applications.

To support their activity, AMS have partnered M&E consultant CAD21, a specialist design house offering comprehensive MEP design services.

Its in-house design team is fully equipped with the skills to take designs from concept to detail design stage and beyond – and get it right first time. Both AMS and CAD21 recognise the impact MEP has on other disciplines, and the importance of setting an MEP strategy that responds to project aspirations and constraints early on.

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2 As a result of working together on the Seismic building, AMS and Tata Steel have collaborated further to provide an enhanced offering to the market, by combining the attributes and benefits of the Tata Steel ‘Trimawall System’ and the Apex Modular Wiring system.

Similarly, AMS are now providing complete building management systems via the Atamate ‘atbos’ (Atamate Building Operating System) software platform that connects both sensors and hardware to their cloud software, which together provides a totally integrated system. Real-time monitoring and control capabilities empowers owners, operators, and facility managers, to optimise energy consumption, HVAC systems, lighting, natural ventilation, and door entry systems remotely.

3 and latterly their site-borne activity.

Gaining a better understanding of the client’s products and process has allowed us to develop and tailor our solutions for maximum benefit, both within the factory and on-site.”

BY INTEGRATING MULTIPLE SYSTEMS WITHIN THE AMS SCOPE OF SUPPLY, THEY CAN PROVIDE A COMPREHENSIVE MEP AND CONTROLS SOLUTION TO ALL BUILDING TYPES ACROSS DIFFERING SECTORS. “Working collaboratively with likeminded and innovative companies,” says Mike Lewis, AWS Business Development Director. “Has allowed AMS to provide a more comprehensive and beneficial solution to clients, who then derive significant benefits, both during their manufacturing process,

AMS are operating across and delivering projects in key sectors within the offsite manufacturing sector, including healthcare, education, Ministry of Justice (MOJ), Ministry of Defence (MOD) residential and retail.

Within the hire market, the benefits of utilising pre-manufactured components for mechanical and electrical services, has the ongoing, and significant benefit of reusability.

The reuse of system components provides significant and sustained commercial benefit throughout the lifetime of the building, as well as providing wider sustainability and environmental benefits.

The value of AMS’s services will be increasingly recognised as more and more clients adopt an innovative

4 approach to delivering M&E services.

Whilst the principal driver is efficiency to aid productivity, a host of cascade benefits result from the adoption of Pre-Manufactured Value (PMV) within the buildings where they are deployed, including carbon reduction, health and safety, waste and programme certainty.

Paul Charlton the newly appointed Operations Director at AMS, said: “We’ve been blown away by the response we’ve had from the market to our proposals and the receptiveness of clients to explore new ideas and to adopt new ways of working. To be working within a growing sector, which is willing to embrace change to meet the challenges increased demand is placing upon the supply chain, is extremely exciting and rewarding.”

For more information visit: www.apexwiringsolutions.co.uk Images: 01-04 AMS provide both mechanical and electrical services for the offsite building sector in a progressive and innovative way

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CONSISTENCY IS KEY

Scott Moran, Operations Manager for NG Bailey Offsite Manufacture, outlines how an ‘offsite first’ approach could help build a safer, better, faster and greener future for MEP.

1 Despite Modern Methods of Construction (MMC) long being touted as the silver bullet that will transform the industry, it is still relatively underutilised, with MMC accounting for less than 5% of the total construction market in the UK. At NG Bailey we have been championing the use of offsite manufacture for decades and it is an integral way of how we approach every project in our business. Through this and our specialised offsite manufacturing facility in Bradford, the largest of its kind in the UK, we deliver projects in a way that is significantly more efficient than traditional construction methods.

As part of this we are working towards achieving World Class Manufacturing Status in our offsite manufacturing facilities, helping us to build on our ‘offsite first’ approach and lead the way in delivering an industry that works more greenly, safely and efficiently.

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2 Delivering safer MEP solutions One of the well-known benefits of MMC is that it transfers many of the hours spent on construction sites to a more controlled factory environment.

In MEP this is especially beneficial, allowing us to construct complex mechanical and electrical engineering components within a factory setting, greatly reducing the risks of working on-site, as well as reducing time spent working at height and manual handling.

This has been transformative in our business, allowing us to achieve an industry leading Accident Frequency Rate of 0.02, one of the lowest in our sector, and 12 years RIDDOR-free in our offsite manufacturing facilities.

However, we never take our eyes off safety. We continue to champion a ‘Safety First & Foremost’ culture within our business, both in our factory and onsite, through initiatives such as our ‘Don’t Walk By’ (DWB) system, which encourages our colleagues to record and act on potential safety issues.

Better quality and performance An MMC approach also offers the opportunity for improved consistency and precision of output, which is imperative in all areas of construction, but particularly MEP. We have championed this through the creation of a standard product solution for most applications, which ensures our customer’s requirements are delivered more efficiently and with a higher level of quality.

These standard products consist of a pre-designed proven ‘kit of parts’ solution, which means that designs are already developed in most parts, leading to more efficient delivery and increased standardisation across projects. This could be revolutionary if adopted more widely across the MEP sector, allowing for a ‘plug and play’ solution with increased performance that can be installed more efficiently.

As part of our aim to continually focus on improvement and innovation, we are helping the wider industry to adopt MMC techniques by driving research

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and development into improved techniques that can increase efficiency of delivering solutions. This includes partnering with the Manufacturing Technology Centre (MTC) as part of the Construction Innovation Hub, which is currently developing solutions for projects such as the New Hospitals Programme and the Department for Education.

Having a common MMC language across the industry is also something we are championing. We are a key part of the BESA Offsite Group, driving specialist knowledge across a wide range of high-level specialist projects.

To ensure that the solutions are manufactured as efficiently as possible, we have also invested extensively in training techniques. These include 6S, Kaizen, and production automation that enables us to be at the forefront of world class manufacturing.

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Faster project delivery As well as increased quality and performance, MMC also has benefits for improving the speed of delivery for MEP projects, both in the manufacturing and the installation process. This is most vital in settings where speed of delivery is crucial, such as hospital and healthcare settings, where reducing disruption and down time is key.

When it comes to delivering multiple large-scale facilities quickly and efficiently, there are a multitude of benefits in creating a kit of parts that can be manufactured offsite and slotted together. For a project at Chesterfield Hospital where we had to work on a live hospital site, our use of a kit of parts solution ensured that we were able to refurbish their existing surgical department while ensuring adjacent theatres could still function.

This approach minimised disruption and ensured patience care was maintained throughout.

We have also been championing increased efficiencies in our factory as part of our journey towards World Class Manufacturing status. This includes embracing a digital factory future through implementing digital solutions that utilise NFC, RFID and 2D barcoding technologies. Handheld portable devices are used to track the component parts through goods in, kitting, assembly, dispatch and, in the future, receipt of the product at the

4 customer’s premise. This will make our processes easier, more efficient, and more auditable.

36,000km of vehicle movements, which alone saved six tonnes of carbon from entering the atmosphere.

Delivering for a greener future Most vitally, MMC offers an opportunity for a greener future for the built environment, which currently accounts for 39% of global carbon emissions.

With an increasing number of companies setting science-based targets to reach net zero, putting in place practical solutions that can reduce emissions throughout the construction process is vital.

As a company that has set its own 1.5 degree near term and net zero commitment target, putting in place methods of construction that can directly reduce emissions is vital to reaching our goals, as well as helping us to support our customers on their own journeys. Embracing an 'offsite first' approach offers the MEP industry a clear path to a safer, more efficient, and environmentally friendly future for the construction industry.

MMC and offsite manufacturing reduces labour hours on-site, which reduces vehicle movements, with less people travelling to site and decreased deliveries. At The Forge, where we delivered a kit of parts solution for the first net zero office building in the UK. The removal of over 25,000 on-site labour hours delivered substantial carbon benefits by avoiding over

For more information visit: www.ngbailey.com Images: 01. Scott Moran, Operations Manager, NG Bailey Offsite Manufacture 02-04. An offsite approach offers the opportunity for improved quality and precision of output

NOVEMBER/DECEMBER 2023 | WWW.MEPMAGAZINE.CO.UK

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CASE STUDY

CONTAINERISED & READY TO CONNECT

2 1 IDS, part of M Group Services’ Water Division, was appointed to design and build a containerised process treatment plant by its client IXOM and used offsite manufacture to do it.

By adopting offsite manufacture IDS established a plug-and-play solution complete with a full operating system, including all component parts of the process to allow efficient set up. The plant is based on a tried and tested treatment process that has been used to treat raw water before transferring to further treatment and eventual potable water storage, distribution, and use. This follows a similar arrangement where ID used skid type solutions for on-site installation and hook up.

IXOM Process PIDS was appointed by its client to build and test the first MIEX (Magnetic Ion Exchange) MICo mini plant in the world. The unit was tested and shipped to Rathlin Island where it was successfully installed and commissioned for Northern Ireland Water. The scope of the works included: detailed design of the manufacturing detail, LCP design, build and test, process skid and tank assembly, mechanical build and electrical fit out and factory testing.

These units are ion exchange resin units with a brine regeneration system for organics loading removal as part of potable water pre-treatment process.

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Subsequent to the offsite manufacture of the individual skid and being delivered to site for hook-up, testing, and commissioning, IDS has been engaged to design and build a containerised pilot plant solution.

This container includes entire MIEX pilot, including the contactors, regeneration skid, and HMI/PLC will be installed inside a 40ft high cube shipping container. The shipping container is customised and fitted with the Pilot Plant Control Panel with HMI (Human Machine Interface)/ PLC (Programmable Logic Controller), Regeneration Skid which comprises four separate vessels (Loaded Resin Transfer Tank, Regeneration Tank, Brine Tank and Salt Saturator).

Due to limited space inside the shipping container, two identical contactors will be used side by side.

There is space left between the regeneration skid and the contactors to allow for site connections to the pilot. The two contactors will be located side by side facing each other to equalize flow.

As the unit is intended to move between sites, a shipping container has been selected to house the subassemblies. Future units for permanent installation could again be installed in containers or in kiosks, using offsite manufacturing techniques. The complete assembly has a big impact on the volume of chemicals the client must use in the treatment process.

The water becomes more potable as the system cleans the raw water by removing organic load, reducing costs of chemical supply, deliveries, storage, and pumping.

There is an increase in the offsite approach across the water and wastewater treatment utilities sectors, with standard designs reducing engineering time on projects, getting services to site quicker and completing projects to shorter overall programmes.

These repeated design solutions provide consistency of approach, giving operators a familiarity with equipment over several sites meaning training is reduced, and spares holding can be strategic and more cost effective. The reduced time on-site enhances health and safety performance by reducing the programme and number of operatives on-site. Importantly, quality of build can be checked in the factory before delivery, ensuring the equipment will function when installed and commissioned in a reduced timescale.

Also, using a containerised solution, transport of the unit is via a single delivery thereby reducing repeated transport costs and lowering any projects overall carbon footprint.

For more information visit: www.idsystemsuk.co.uk Images: 01-02. The containerised offsite solution brings a raft of project benefits to the wastewater sector. Courtesy ID Systems

WWW.MEPMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

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kinedo.co.uk

ENSURING PLUMBING QUALITY AT EVERY STAGE

Offsite modular construction is playing a key role in shaping the industry’s future, but it requires a specific approach to design and material choices.

This is especially true for heating and plumbing systems. Paul Whittall, Business Development Manager for MMC at Uponor, explains more. ongoing support and guidance throughout the project is just as important, especially if the scheme is complex or large in scale.

1 While it might sound simple, choosing the right products must be the starting point, as it can make a real difference to the speed, simplicity, safety and even cost of construction. Multilayer composite (MLC) pipe, which combines the benefits of a metal and plastic pipe, with a stable aluminium core and flexible polyethylene outer case, is ideal for offsite construction for several reasons.

MLC pipe in general, is lighter than traditional metal pipe, offers longer pipe runs and requires fewer joints and fittings, as it can be bent rather than cut to achieve changes in direction.

It also typically does not require specialist trades for installation and eliminates the need for hot works, ensuring a lower risk installation and helping to improve health and safety. However, looking carefully at the features of the specific product is important – as with any specification choice – the devil is in the detail and not all MLC pipes will perform in the same way.

For example, our Uponor Uni Pipe PLUS has up to a 40% narrower bending radius compared to conventional multilayer composite pipes. This means it can offer greater versatility and can reduce the number of fittings required by up to 15% due to improved bendability.

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2 The choice of product is not the only consideration when selecting a system. The support offered by the supplier can also make a significant difference and contractors should look for partners that offer more than simply supplying the specified product alongside necessary technical details.

Leading manufacturers will take time to fully understand the requirements of the project so they can provide a more comprehensive and consultative service. At Uponor, we have been working on offsite construction projects for more than 10 years and as a result know how important it is to have dedicated and specialist account managers who work with the client throughout the project.

However, to realise the full the benefits of a partnership-based approach, it is important to bring the system manufacturers into the project as early in the process as possible. This will allow design recommendations to be implemented more easily and cost effectively with less wasted time.

It is always recommended that those installing the system are familiar with the products and informed about the correct installation process. This can help to improve productivity and efficiency as well as prevent installation errors that could present issues at the commissioning stage. Furthermore,

An example of how our approach has worked in practice is the Ten Degrees development – currently the largest modular apartment building in the world. Completed in 2021, the buildto-rent development consists of two towers of 38 and 44 storeys and a total of 1,500 modules. Following the specification of the Uponor multi-layer pipe system, we developed a threeyear partnership with the manufacturer of the modules.

We supplied over 120,000m of MLC pipework and 2,250 manifolds used to supply the hot and cold water to each apartment. Our team also provided full support throughout the project including bespoke training, translated into different languages for all the production employees, as well as advice and checks on installation processes. The manufacture of the modules was completed in just 24 weeks and with a 100% reliability rate from the Uponor products.

Offsite construction has the potential to help solve many of the issues facing the industry, but to maximise the benefits of this approach it requires a close working relationship between the contractor and leading product manufacturers that can offer the required support.

For more information visit: www.uponor.com/en-gb Images: 01-02. It is always recommended that those installing the system are familiar with the products and the correct installation process

WWW.MEPMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

Quality Assured plumbing for modular construction PODS, PODS,Volumetrics Volumetrics and and DfMA DfMA Quality Qualityis isbuilt builtinto intoour ourpipes pipesand and fittings, fittings, making making it it easy easy to to meet meet all the requirements for the supply of domestic water, heating all the requirements for the supply of domestic water, heating or or cooling coolingfor foryour yourmodular modularconstruction. construction.

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MODULAR CONSTRUCTION,

MODULA ELECTRIC Offsite manufacturing of modular, plug-and-play electrical systems.

Our innovative electrical systems, built and tested in a controlled factory environment, are designed for modular construction.

Talk to us about your next modular project.

Rapid project delivery

Offsite fit-out capability (up to 70%) Zero waste on-site

MODULA modulaelectric.com

IDEAL DRAINAGE SOLUTIONS

Martyn Rowlands, Managing Director at Pipekit, is seeing demand for prefabricated drainage systems grow and is busy scaling up the business to cope. including 100% pressure testing, with the test record embedded into the QA report for each stack. The whole process takes place in a controlled factory environment from cutting, welding, testing, and packing without the inclement conditions found on construction sites to maximise quality assurances.

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2 Pipekit is investing in and expanding its dedicated prefabrication service following significant market demand, specifically in the tall building and refurbishment market sectors.

According to Barbour ABI, in the last 12 months there have been 204 10-storey plus projects undertaken in the UK with a total value of £12.3billion and despite the economic uncertainties and tougher safety and sustainability outlooks, the tall building market remains buoyant for the foreseeable future.

City planners and developers, up and down the country, continue to look for ways to make the most of urban space and therefore contractors will increasingly be looking for ways to meet the challenges of catering for the tall building market, as well as the refurbishment of large multi occupancy buildings.

Offsite prefabricated drainage can significantly help contractors change their way of working for the better and navigate some of the complex issues surrounding the design and installation of effective drainage systems in taller structures.

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3 Traditional on-site methods using loose piping products, has an over-reliance on skilled site-based labour, specialist tooling and storage requirements on-site, which can escalate costs quickly. Prefabricated drainage can offer contractors an effective solution to address the skilled worker shortages, at the same time as drive overall costs down and improve the speed, quality, and reliability of the installations.

The biggest value for offsite prefabricated drainage is the enhanced level of quality and control it can offer contractors. When using Pipekit’s prefabrication service, contractors can benefit from utilising a high-quality offsite service that minimises the risks and costs before the product even arrives on-site.

The team will work with the contractor to develop a set of standard stack designs and then manufacture, test and deliver to site. Typically, the service will deliver a level or storey of the building at a time and according to the project’s timings. It also undertakes a 14-point quality control check,

Pipekit’s prefabricated drainage stacks utilise Geberit’s HDPE product, a relatively lightweight material (particularly compared to cast iron drainage), which ensures ease of lifting and working in confined spaces.

The prefabricated nature of the stack designs is also easier and faster to install, compared with traditional methods, which is particularly prevalent for the complexities of managing the build and fit out of tall buildings.

Using a prefabricated drainage service can cost more up front but the overall project cost savings brought by this offsite method are significant.

Plus, when you factor in the ability to increase the reliability of installations, offsite drainage solutions offer an economic, sustainable, and safe option for tall newbuilds or the refurbishment of large multi-occupancy buildings.

Pipekit can fabricate bespoke stacks up to 315mm in diameter, using Geberit HDPE, Silent db20 and Solvent drainage fittings and Pipekit is currently fabricating drainage for two prestigious tall building projects in Birmingham.

For more information visit: www.pipekit.co.uk

Images: 01-03. Prefabrication in the factory provides products that are easier and faster to install, compared with traditional methods

WWW.MEPMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

PRODUCT:

MECHANICAL ELECTRICAL & PLUMBING

MODUL AR INNOVATION ENERGY EFFICIENT MEP PODS | A CENTRAL HUB FOR HEATING, VENTILATION, WATER MANAGEMENT, COMMUNICATIONS AND ELECTRICAL SERVICES For detailed and up to date information, to attend a factory tour or arrange a meeting please contact our team today.

T: +44 1743 290020

W W W.VOLUMETRIC.CO.UK

Designed, engineered and manufactured by our multi award-winning offsite experts, VOLUMETRIC’s MEP Pods arrive on site fully assembled, rigorously tested and certified, ready for simple ‘plug and play’ installation.

CASE STUDY

RISING POWER WITH VOLUMETRIC™ 2023 WINNER

1 Due for overall completion in 2026, Kew Bridge Rise is a major residential development on the site of a former Citroen garage in Brentford, West London and will feature the latest in bathroom and MEP pod technology.

This ambitious project saw ground broken in 2022 and is set to bring over 400 high-quality, sustainable homes to the area. The project team behind the development selected VOLUMETRIC™ to provide the design, engineering, manufacture and installation of bathroom and MEP pods from VOLUMETRIC™’s new range.

Kew Bridge Rise is a collaboration between Hill Partnerships and housing association L&Q and forms a key element of the ongoing regeneration plans throughout the area. With a proven track-record of designing and manufacturing award-winning offsite solutions, the VOLUMETRIC™ team worked collaboratively with suppliers and the client to achieve the precise, bespoke specifications required for the brief.

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Speed, efficiency and value were integral aims for VOLUMETRIC™, who fast-tracked the range of bathroom and MEP pods following extensive research and development. The pods supplied by VOLUMETRIC™ provide a single source solution to the specification, procurement and installation of MEP services to the site.

The first delivery of pods was made in spring 2023, following the installation of full-sized display pods at the development site earlier in the year. Super-efficient and offering outstanding quality, the pods combine precision engineering with advanced digital technology – reducing standard installation times by up to 90% and offering 94% pre-manufactured value (PMV).

Prior to delivery, VOLUMETRIC™’s expert team worked with the client to provide highly accurate design plans and BIM modelling using the latest Revit digital technologies, supported by 3D printing software and augmented and virtual reality prototyping. This allowed the design team to achieve a truly bespoke

WWW.MEPMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

finish that met the project’s exact requirements. VOLUMETRIC™ then manufactured the pods using a DfMA approach in their advanced factory facilities using a lean, mass standardised and process-driven approach.

The bathroom pods produced for Kew Bridge Rise were ergonomically designed for maximum spatial efficiency. Using the unique Slimwall™ technology and integrated underfloor heating solution, the pods were customised with finishings specially selected by the client, including showers, taps, sinks and bath fittings.

Environmentally friendly and energyefficient, the pods use controlled flow showers and dual-flush cisterns to mitigate water waste. The technical team at VOLUMETRIC™ completed rigorous testing of all plumbing runs prior to dispatch to negate the chance of leaks or remedial works following on-site commissioning and reducing the expense and time spent on snagging activity.

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Trevor Richards, Operations Director at VOLUMETRIC™, explained the approach to the project:

“OUR AWARD-WINNING RANGE OF BATHROOM AND MEP PODS FIT PERFECTLY WITH THE CLIENT REQUIREMENT FOR TECHNOLOGY THAT IS BOTH FAST AND EFFICIENT, BUT ALSO SUSTAINABLE – ENHANCING THE WHOLE BUILDING. OUR APPROACH WAS TO UTILISE THE INHOUSE SKILLS OF THE VOLUMETRIC™ ENGINEERING AND DESIGN TEAM, WORKING CLOSELY WITH OUR TRUSTED SUPPLIERS TO ENSURE EXACT SPECIFICATIONS WERE MET AND THE CLIENT EXPECTATIONS EXCEEDED.” The MEP pods, which will provide the mechanical and electrical services to Kew Bridge Rise, respond instantly to water, heating and digital communication requirements. The decision to use VOLUMETRIC™ MEP pods provided particular benefits to Hill Group and L&Q, removing the requirement for traditional MEP activity on-site and decomplicating the co-ordination of additional service providers. This allowed for a smooth and seamless delivery requiring minimal labour to install, with all the pod types being installed by the same team.

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The Kew Bridge Rise project is currently on schedule with plans to potentially speed up the delivery of the new homes. A topping out ceremony was recently held on 23 September, less than a year after the groundbreaking onsite. Trevor Richards added: “It is great to see the Kew Bridge Rise development progressing. VOLUMETRIC™ is proud to have supplied the bathroom and MEP pods for the project, which will bring much needed quality homes to West London.”

Kew Bridge Rise will comprise a mix of one- and two-bedroom apartments, half of which will be available through shared ownership and affordable rent schemes. The first residents are expected to move in by autumn 2024.

For more information visit: www.volumetric.co.uk Images: 01-05. Kew Bridge Rise, Brentford, West London

The VOLUMETRIC™ range recently took home the Best Use of MEP & Pod Technology at the annual Offsite Awards, recognised by the judges for being an energy-efficient solution that harnesses a data-driven approach to improve efficiency and speed up building times.

NOVEMBER/DECEMBER 2023 | WWW.MEPMAGAZINE.CO.UK

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ADVERTORIAL

TRANSFORMATIVE TECHNOLOGIES FOR THE CONSTRUCTION INDUSTRY Unipart Construction Technologies is combining optimised digital design with advanced manufacturing techniques to deliver transformative solutions to the construction industry’s biggest challenges. comply in a range of applications with independent validation by the Integrated Civil and Infrastructure Research Centre and Sheffield University.

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2 Laser Cut Reinforcement (LCR): revolutionising structural concrete reinforcement LCR technology delivers a range of benefits that improve the quality, strength and efficiency of reinforced concrete building components including: optimised design, faster manufacture and assembly, on or offsite casting, and safer assembly and installation without the need for specialist steel fixers.

Dave Allen, General Manager, Unipart Construction Technologies says: “LCR is a pioneering technology for structural concrete applications that uses advanced engineering techniques for laser cutting and joining steel, adapted from the automotive and aerospace sectors, and specialist digital optimisation tools to deliver

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3 a modern concrete reinforcement solution.

“The construction industry, and concrete in particular, is one of the biggest emitters of CO2, and while the industry is on a journey towards net zero, there needs to be a solution to the sustainability challenge. Our customers can already see LCR is a major way to lower their carbon footprint. By utilising LCR they are reducing the amount of concrete and steel in areas of construction that depend on reinforced concrete.”

LCR’s optimised digital design can support a 20-40% reduction in the use of concrete and steel in an integrated construction solution. LCR is designed to comply with all industry codes and regulations, and is proven to

Optimised Modular Assemblies: streamlining construction processes Unipart Construction Technologies’ optimisation, design for manufacture and assembly (DfMA), and advanced joining technologies are also applicable to other structural applications. Modular frames can be designed to support offsite manufacture and modern methods of construction (MMC). The technology can replace traditional fabricated/ rolled section frames and provides a range of benefits including automated design and analysis to facilitate bespoke solutions, faster manufacture and assembly, and laser cut tolerances of +/- 1mm.

Concrete Moulds and Ancillary Tooling Solutions: boosting productivity, quality and speed Unipart Construction Technologies draws further on Unipart’s precision engineering and manufacturing solutions to provide a range of concrete moulds and ancillary tooling products that offer turnkey solutions for our customers including: moulds, assembly tooling and lifting solutions.

Unipart Construction Technologies is providing structural components to a number of major UK construction projects with residential and commercial applications.

For more information visit: www.linkedin.com/company/unipartconstruction-technologies Dave Allen, General Manager; dave.allen@unipart.com Michael Starr, Commercial Manager; michael.starr@unipart.com Images: 01-03. UCT is combining optimised digital design with advanced manufacturing techniques

WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

DATES FOR YOUR DIARY 2024 If you are interested in learning more about offsite construction and the associated manufacturing processes then the following industry events may be of interest: 19 & 20 March

Modular Matters

Coventry Building Society Arena

www.modularmatters.co.uk

With a wider and more diverse programme than ever, Modular Matters brings together volumetric modular innovators and change-leaders to separate the facts from fiction and determine the actions needed to make radical transformative change.

16 April

Structural Timber Conference

Birmingham

www.structuraltimberconference.co.uk

Celebrating the success and leading the conversations shaping the future of timber. In a world of increasing focus on circularity and sustainability, the 2024 conference asks ‘what’s important right now?’ for the structural timber sector.

14 May

Focus on Framing

FOCUS ON

FRAMING

22 & 23 May

Birmingham

www.focusonframing.co.uk

In partnership with the Light Steel Frame Association (LSFA), this seminar offers a deep dive look at the systems and technological advances improving design platforms, building safety and sustainability performance.

MMC Ireland National Conference

The Lyrath Estate, Kilkenny

www.radarbookingsystem.co.uk/mmcireland-national-conference-2024

One of the latest and most well-received additions to the offsite industry calendar, MMC Ireland National Conference offers fresh perspective and insight into the trends, technologies and engineering innovation driving the Irish offsite construction market.

25 June

Tall Building Conference

Central London

www.tallbuildingsconference.co.uk

Bringing together highly influential experts from across the sector, Tall Buildings Conference 2024 will focus on the progress of building safety, structural performance and the design advances bringing iconic high-rise builds to the UK skyline.

25 June Tall Buildings Awards

17 & 18 September 2020 Tall Buildings Awards

Tall Buildings Awards 2020

17 September 2020

Tall Buildings Awards

2024 Tall Buildings Awards 2020

Tall Buildings Awards 2020

02 October

Tall Building Awards

Co-located with Tall Buildings Conference

www.tallbuildingsawards.co.uk

Recognising extraordinary contributions in the advancement of the superstructures that are shaping our urban landscapes, the Tall Buildings Awards celebrate architectural ingenuity, engineering prowess and the innovations that are transforming the digital design and construction arena.

ENTRY DEADLINE: 15.03.24 Offsite Expo

Coventry Building Society Arena

www.offsite-expo.co.uk

OFFSITE EXPO brings together those who are driving change in the construction sector – the event will play host to the leading UK and international offsite manufacturers and component suppliers over two days in September 2024.

Offsite Awards 10 YEAR ANNIVERSARY

Co-located with Offsite Expo

www.offsiteawards.co.uk

Recognising the iconic projects from across the offsite sector, the Offsite Awards showcase the people and businesses pioneering the new technology, building methods, systems and designs raising the standards of safety, sustainability, social and financial value in construction.

ENTRY DEADLINE: 31.05.24 Structural Timber Awards 10 YEAR ANNIVERSARY

National Conference Centre, Birmingham

www.structuraltimberawards.co.uk

Now in its tenth year, the Structural Timber Awards promises to be bigger, better and more inspiring than ever. The 2024 awards will reward the companies instigating change, delivering outstanding projects and raising awareness of the efficiency, reliability and sustainability of structural timber.

ENTRY DEADLINE: 21.06.24 05 & 06 November

C O N F E R E N C E

05 November

Innovate Conference

Birmingham

Website Coming Soon

Innovate will bring together those with the insight to evaluate transformative innovations and explore how they can be used in a real-world context to radically advance how buildings are designed, developed and delivered.

Innovate Awards

Co-located with Innovate Conference

Website Coming Soon

Rewarding all those designing and developing the future of construction technology. This exciting inaugural event will throw the spotlight on the booming Industry 4.0 and the world of digital tools, smart construction and sophisticated new ways transforming the built environment.

ENTRY DEADLINE: 12.07.24 04 December

Construction Productivity Conference

Central London

www.constructionproductivity.co.uk

Bringing together a host of industry leaders to discuss strategy, opportunity, and the future of productivity in the built environment. Delegates will have the opportunity to learn about new practices from those at the forefront of construction productivity.

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WWW.OFFSITEMAGAZINE.CO.UK | NOVEMBER/DECEMBER 2023

TRAILBLAZERS IN LIGHT STEEL SOLUTIONS Frameclad are keen and fiercely competitive. From standard infill systems to vast light steel frame developments – every project gets the same exceptional quality as standard and unrivalled customer service.

A Winning Combination

AGILE Cost estimates in 10 days and detailed designs within one week

ADAPTABLE Can do attitude with the ability to tackle any job large or small

ADDED VALUE A 12-strong in-house team delivers design and engineering services

ADVANCED Produces one of the largest ranges of steel sections available in the UK today

ASSURED Fire test data provides confidence to construction and public sector clients

Call in the ‘A’ Team Tel: 01384 401 114 Email: enquiries@frameclad.com Visit: www.frameclad.com