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DECARBONISE WITH A NEW ERA OF LIGHT STEEL FRAME
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AUTOMATED OFFSITE
The future of the construction sector is going to be heavily driven by technology and digital tools
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LOW CARBON HOUSING
How to build more homes, hit government targets and still reduce levels of construction carbon
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PRISON DESIGN
Tackling overcrowding in UK prisons is a priority and volumetric modular construction can help
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Welcome to the new edition of Offsite Magazine. As befitting the issue that is freshly minted and available at OFFSITE EXPO, inside you will find the usual wide range of news, case studies and some wise words from the Offsite Construction Week Advisory Board.
Many individuals that spend their everyday working lives in the offsite construction world – and those of us that spend a decent amount of time observing and reporting on it – will have felt that over the last couple of years the reputation and interest in offsite/MMC (and everything those words encapsulate) has reached new heights of acceptance and understanding, to see it dented by high-profile business failures. Certainly, the perceived short-termism of deep pocket investors plus some muddled tactics on system development, have created clickbait headlines that have been accepted by some as proof that offsite is of limited value and/or fraught with risk.
The reality is that the construction sector has been trading through some of the worst macro-economic conditions in decades with insolvencies overall worryingly high. In a wider context the offsite sector has fared well against the backdrop of soaring costs, interest rate hikes, supply chain
and material pressures and the skills shortage that show little sign of changing.
The new Government’s plan for Skills England must embrace the changing world of construction. The advent of digital tools and software developments, robotics and futuristic manufacturing environments are fertile opportunities to attract newer, younger and more diverse groups of industry entrants. This thinking is at the centre of the offsite equation. Earlier this year, Tim Balcon, CITB Chief Executive, said they had embarked on a “paradigm shift in thinking around construction skills.” Alongside schools of architecture, it is hoped that the benefits of factory-based building design are not sidelined in this.
That’s my stir of the pot. Inside we have a few other ‘Offsite Opinions’ of various flavours and with OFFSITE EXPO on the horizon – or right now if you are reading this in Coventry – you will have many opportunities to hear from the numerous thought leaders, change makers and industry champions all in one place.
A special thanks as always to our contributors, advertisers, and supporters for their help this issue. It is always genuinely appreciated.
Gary Ramsay Consultant Editor
Email: gary.ramsay@offsitemagazine.co.uk
COVER STORIES
With the construction industry increasingly under pressure to become more sustainable, Metsec Decarb provides a reduced carbon future for the construction industry. It does not rely on the smokescreens of green washing, mass balance, carbon offsetting or the allocation of green energy for its environmental credentials.
Andrew Carpenter, CEO of the STA believes offsite manufacture and carbon friendly timber could lead the way in helping Labour achieve its 1.5 million homes target in a new era of construction and housebuilding. The commitment to more homes is ambitious but with the right policies and systems it can be done.
Eva Magnisali, Founder & CEO of DataForm Lab, spoke to us about why accelerating the adoption of automation in offsite construction is central to a successful future industry and why the future of building design and delivery is almost certain to be technology and digitally-driven.
The UK’s prisons are full to bursting point, creating a critical issue for the new Government. Chris Turner, Managing Director of Integra Buildings, examines the vital role modular construction can play in addressing the prison overcrowding crisis with high quality new facilities.
FEATURES
08 | Industry News
News and developments from across the UK offsite industry and wider construction arena including: DIO appoints six companies to build new armed forces living accommodation, Thurston Group reveals positive financial results despite challenging market conditions, more airspace developments in London and LHC appoints new Director of Product Innovation.
28 | Ask the Offsite Experts
In the run up to OFFSITE EXPO 2024, we pooled some comments from some of the Offsite Construction Week Advisory Board on where the world of offsite sits from their individual perspective.
40 | Modular is the Answer –What is the Question?
Adam Salt, Business Development Manager for A.Proctor Group, assesses expectations around quality in the offsite sector and the use of measurement techniques.
50 | A New LEAF in Offsite Delivery
Frameclad is launching its Lightweight Engineered Adjustable Frame (LEAF) system at OFFSITE EXPO – what’s involved and how will it change the face of light steel frame design?
62 | Formula for the Future
Following an investment of over £10million, Donaldson Timber Systems has increased capacity and boosted technical capabilities at its Witney facility to create a state-of-the-art manufacturing process
78 | Tunnel Vision on Decarbonisation
MPA Precast tell us more about the Silvertown Tunnel linking Silvertown to the Greenwich Peninsula and why calcined-clays deliver a circular economy solution for tomorrow.
86 | Shaping a Sustainable Future with MMC
The ecological clock is ticking, and designers must take urgent action. Richard Hipkiss, Development Director of the MPBA explains how volumetric technology can support net zero targets.
88 | High End Modular Living
In a constantly developing and changing modular construction world, PBSA is a thriving sector. As part of this growth, Stelling Properties are forging ahead with many successful projects.
90 | Time for Transformation
As part of our Offsite Opinion series Jaimie Johnston MBE, Bryden Wood’s Head of Global Systems spoke to us about the role of DfMA in transforming construction.
94 | AI Awareness Lessons Required
With artificial intelligence seemingly becoming a part of everyday life, recent research from BSI suggests the built environment sector is currently one of the least prepared to make the most of it.
REDUCING CARBON CONTENT
The construction industry is increasingly under pressure to become more sustainable. By using Metsec Decarb the steel and offsite sector can enter a new era of low carbon design.
There is no escaping the fact that the construction industry is responsible for a significant proportion of global greenhouse emissions and the pressures to change are enormous – particularly from government, but also from local planning regulations, public bodies and the industry itself, with designers, clients and developers seeking to minimise a project’s carbon emissions and environmental impact.
Deciding whether to adopt such processes may not be entirely voluntary either, as central government and local authorities are already putting policies in place to encourage a greener approach to all areas of their operations, a trend which seems likely to continue in the future.
Together with other environmental initiatives, such as the London Plan 2021, which requires medium- and large-scale construction projects in London to have an Environmental Product Declaration (EPD) and
1carbon footprint statements as part of the planning application, these policies place increased pressure on architects to design buildings which can be constructed using sustainable materials and methods.
Consequently, everyone in the supply chain is placed under increasing scrutiny, from the materials manufacturer to contractors, installers and sub-contractors. Every process will have an impact on the environment in some way and have implications for the carbon footprint of the project. The challenge is to make these processes carbon neutral.
Material challenges
When it comes to materials, the challenges are considerable; the major building materials used today, and likely to be used for centuries to come, all have some impact on the carbon content of a building project. This is true of concrete, bricks, steel, plastics and timber.
The carbon content can be from a variety of sources: The natural material’s intrinsic carbon content, the processes used to extract the materials, their conversion into usable raw materials, conversion/production processes and all the supporting functions that contribute towards a product being used, from sales and administration to storage and transportation.
There is also the question of whether this carbon remains embodied within the material after the life of the building, such as when metals are recovered, recycled and/or repurposed, or released into the environment - for example, where timber cannot be re-used and might be burned.
Steel yourself
Any connection between steel and sustainability might not be immediately obvious to many, but its credentials make a compelling case for its use in construction, with light gauge steel framing systems, such as Metsec SFS and Metframe, delivering additional benefits. These include:
• Steel is easily recoverable and is 100% recyclable – SFS has a reuse and recovery rate of 85%, compared to just 13% for timber
• Reduction in a structure’s embodied carbon by using less steel
• Accurate design and manufacturing processes result in virtually zero waste
• SFS is a lighter material, reducing the environmental impact of transportation.
There is no escaping the fact that steel manufacture is one of the largest global contributors to CO2 emissions, but European steel manufacturers are making great strides to move away from fossil-fuelled processing by using less carbon-intensive electric
COVER STORY VOESTALPINE
arc furnaces which are powered by renewable energy to create a reduced carbon steel.
Andy Hackett, General Manager of voestalpine Metsec’s Dry Lining Division, states, “Metsec Decarb is a prime example of this drive towards reduced carbon steel. Available for Metsec SFS, Metframe, internal non-loadbearing dry lining studs and purlins, Metsec Decarb is a true move towards a reduced carbon future for the construction industry. It does not rely on the smokescreens of green washing, mass balance, carbon offsetting or the allocation of green energy for its environmental credentials but stands by its own impressive outputs; compared to blast furnace manufactured steel.
“When used for Metsec Framing and Purlins products, Metsec Decarb achieves a reduction in CO2 emissions of 54.7%, whilst in Metsec Dry Lining products the reduction is 65.35%. In each case, Metsec Decarb contains less than half the amount of carbon dioxide per tonne for the same quality of steel (accurate in July 2024).
“The reductions in CO2 achievable with Metsec Decarb can be balanced against the 30-year London Plan offset charges or to help achieve other, everincreasing sustainability targets.”
Society aims
The carbon within the material itself makes a significant impact on the carbon content of the building. However, as mentioned, there are many additional inputs which can contribute towards the environmental impact of the building and the
materials used in it – the processes used in manufacturing, administration, storage and distribution. There seems little point in a building materials/ systems manufacturer offering a reduced carbon product if the same manufacturer is not committed to reducing the carbon dioxide emissions of its own operations.
Net zero carbon forms part of the government’s procurement policy, with the Cabinet Office’s Action Note PPN06/21 stipulating how government departments need to take account of suppliers’ Net Zero Carbon Reduction Plans when procuring for major government contracts. Whilst governments at home and abroad may be wavering on their commitment to achieving net carbon zero emissions by 2050, there can be little doubt that the objective will remain an integral part of policy in the future, even if the deadline is extended.
Andy Hackett continues, “Manufacturers and suppliers will still need to look at ways in which they can reduce their carbon emissions. As part of voestalpine AG, Metsec remains committed to achieving net zero carbon emissions by 2035, investing in new systems and equipment to reduce carbon emissions throughout its operations.
“Achieving this industry-leading target requires a focused effort within Metsec together with the co-operation of suppliers and others in the value chain. This includes investigating areas where we can save energy and optimise processes as well as exploring ways to source green electricity, or even generate our own renewable energy.
“Moving our electricity requirements to 100% renewable sources has resulted in a 67% reduction in our carbon footprint and by the end of this Summer we will have installed enough solar PV panels to generate 48% of our total electricity requirements.
“Further measures aimed at reducing our impact on the environment include a host of energy-saving schemes throughout our facilities, replacing company cars with hybrid and electric vehicles, installing charging points across our site, switching forklift trucks from gas to electric and reducing overall gas consumption.”
Carbon guarantee
As with most things in life, achieving a desired result – for example constructing a net zero carbon building – will rely on striking a balance between the ideal and the achievable. Faced with a design brief to minimise a building’s carbon footprint, steel might not be the first building material which comes to an architect’s mind. But, on closer inspection, steel, and reduced carbon steel in particular, offers a viable solution when all factors are considered, especially when used in the manufacture of efficient construction solutions. Specifiers can take added assurance of product/ system credentials from manufacturer statements and EPDs which can be included in the final project’s carbon assessments.
For more information visit: www.voestalpine.com/metsec Images: 01-03. Metsec Decarb is a prime example of the drive towards
UK INDUSTRY NEWS
New Airspace Development for Wimbledon Chase
Castlemere Developments is committing more than £1.8million to a new five-apartment airspace development in Wimbledon Chase. The Windsorbased property developer has already invested more than £400,000 to purchase Vision House, an art deco building located on Kingston Road.
The scheme at Vision House will feature one three-bedroom, two two-bedroom apartments and two one-bedroom apartments. The apartments will cost from £385,000 up to £650,000 once on the market. Having completed the purchase of property in August, work will now commence on constructing the apartments. These will be built offsite using modern methods of construction (MMC). It is expected that the project will be completed by spring 2025.
This acquisition and plans for Vision House follow the completion of Castlemere Developments’ first completed airspace project in Tunbridge Wells, which has 11 apartments. Castlemere Developments is in the process of securing a number of locations across the South East, which will see the company provide a mix of airspace developments and ground-up properties.
MOD Announce Single Living Accommodation Pipeline
The Defence Infrastructure Organisation (DIO) has announced the appointment of six companies to build Single Living Accommodation (SLA) for the armed forces. The six companies – Bowmer and Kirkland, ExtraSpace Solutions, Kier McAvoy, Kier Metek, Laing O’Rourke and Reds10 – will be awarded contracts through an existing Crown Commercial Services framework.
Each company submitted a tender to be considered for the new alliance, which was rigorously assessed on a range of requirements by DIO and their technical support provider, Arcadis. The alliance, which will run for six years, will see 16,000 new bedspaces built as part of a wider-MOD plan to build or refurbish 40,000 SLA bedspaces over 10 years. The work will improve the lived experience for service personnel occupying the rooms. The appointment of the six companies is part of DIO’s new programmatic approach for SLA, which is intended to improve the delivery of new accommodation by finding efficiencies and improving value for money.
A library of SLA designs has been created with a common base design, and flexibility to adapt to the needs of the site and its personnel, such as the
The company has purposely committed to offsite to enable it to deliver projects much quicker than on-site developments, reduce the disruption to current residents, and ensure its developments are as environmentally friendly as possible.
Kris Collett, Managing Director of Castlemere Developments, said: “Vision House is the latest addition to our portfolio which will feature five high spec apartments, which will include smart home technology. Vision House, which was originally an office block, has already undergone conversions to 19 apartments inside the original structure. It also has four commercial units on the ground floor.
“I expect to commence work on building the apartments in the autumn and for them to be lifted into place in the first quarter of 2025. The aim is to have the apartments on the market from spring 2025. This is a vibrant location, with access into London. We are aware there is a huge demand for residential properties, and this is just one of a number of locations that we are developing to help meet this need.”
Source: www.castlemere-developments.co.uk
number of rooms required. The designs can be used for accommodation intended for short-term occupancy, such as recruits undergoing initial training, as well as permanent accommodation in military bases.
While the SLA design catalogue allows for different construction methods enabling adaptability, the SLA programmatic approach focuses on modern methods of construction (MMC), with new blocks built offsite. This should improve the speed of manufacture and reduce the time spent on-site, minimising disruption. The designs were created with sustainability in mind and will contribute to the Government’s Net Zero Carbon strategy. The alliance will champion collaborative behaviour and innovation to improve delivery, learning from each completed project and using that knowledge to improve the next.
Charlie Hoskins, DIO’s Director of Major Programmes and Projects, said: “I am convinced this new alliance using a programmatic approach will be crucial to improve our broader delivery of Single Living Accommodation. These blocks are one of the armed forces facilities we build the most, and this approach will ensure we can safely build blocks faster, to a common design, ensuring consistency of standards and driving better value for money.” Over the next two years, a hybrid approach will be adopted with the full new approach being used for all projects from 2026 onwards.
Image: Representatives from DIO and the successful firms at a recent mobilisation day for the new approach. Crown Copyright.
According to a report published recently by healthcare facilities experts Darwin Group and Portakabin, harnessing the potential of flexible modular buildings to directly reduce the NHS backlog of some 7.6 million individual cases can help transform the future of the service and make it secure for the long term.
The report titled: ‘The End of the Waiting Line’, commissioned by Portakabin and endorsed by the NHS Trust membership organisation NHS Providers, concludes that the ageing NHS estate, which carries a staggering ongoing maintenance cost of £11billion, can benefit directly from a holistic approach to the patient journey which factors in the use of adaptable clinical and non-clinical buildings to safeguard patient care, safety and staff support. These flexible spaces can be added to existing hospital buildings in a matter of weeks, offering an instant solution to allow patients to be seen and treated more quickly.
“Contrary to some beliefs, the safety and quality standards of modular buildings are equal to those of long-standing facilities across the NHS Estate,” said Nick Dawe, Director of Strategy and Transformation, Darwin Group. “As the new Labour administration seeks to put the future of the NHS at the centre of its policy agenda, the new report acts as an important reminder of the need to think holistically and flexibly about how the NHS is managed. Eating into the incredibly high list of patients waiting to be treated is a critical priority to ensure the service is sustainable, and a cost-effective approach to integrating modular buildings and spaces, whether used for operations or other forms of patient care, is vital to achieving that reduction.”
The report isolates five key steps which the authors believe can deliver a fully sustainable future for the NHS. Beyond the adoption of a system-wide approach to securing the NHS Estate, it recommends increased collaboration between different NHS disciplines, a focus on workforce wellbeing by including a clinical perspective on staff management, a plan to actively consider the adaptability of existing
The report also makes the case for considering purpose-built facilities designed to optimise resources to be more energy-efficient and environmentally conscious, via reducing the number of buildings which are no longer suitable for clinical use and focusing on adaptable strategies which directly impact waiting times and allow patients to be seen, diagnosed and treated more efficiently. By doing so, the NHS can not only reduce its impact on the environment but be more flexible in adapting to the likely future needs of individuals as the UK population continues to age and chronic diseases requiring ongoing management become more common.
“We understand the critical role that estates and facilities play in safeguarding the future of the NHS and its patients,” said Dan Ibbetson, Chief Executive Officer, Portakabin. “For this reason, we are proud to launch the Five-Point Plan, ‘The End of the Waiting Line’, which has been timed to support the newly formed Government and health and care colleagues in addressing urgent system priorities.
“To strengthen our healthcare expertise, Portakabin acquired Darwin Group last year, a specialist in healthcare construction with over 18 years of industry experience. This partnership has significantly enhanced our combined capacity and speed, enabling us to deliver high-quality clinical and non-clinical buildings swiftly to meet immediate NHS needs. Together with the teams at Portakabin and Darwin Group, I stand with our health and care colleagues as they navigate the ever-changing landscape of care. We look forward to welcoming supportive and decisive action from the country’s leadership to protect and safeguard not only the future of the NHS, but also the safety of its patients and workforce.”
Source: www.darwingroup.co.uk
James Jones & Sons Timber Systems Division Celebrates 25 Year Milestone
James Jones & Sons Ltd has announced the 25-year anniversary of its Timber Systems Division based in Forres. The Timber Systems Division was launched 25 years ago as the UK’s first I-Joist production line and has since grown to become the UK’s largest manufacturer of certified I-Joists, branded as JJI-Joists. Today JJI-Joists have a 40% share of the UK’s I-Joist market and are used by every major UK housebuilder in addition to supplying customers across Europe, Australia and New Zealand.
Tom Bruce-Jones, Chairman of James Jones & Sons Ltd, said: “This is a major milestone for the Timber Systems Division and the extensive programmes of capital expenditure and innovation. Since its inception we have produced well in excess of 100 million lineal metres of JJI-Joists and stored over 455 thousand tonnes of embedded carbon in approximately one million new homes. In recent years developments have included £8.5million investment into the commissioning of a new world leading I-Joist production line, a stock yard extension and the addition of JJI-Wall stud to our EWP portfolio to help housebuilders meet new Part L building regulation requirements.”
Angus Macfarlane, General Manager of Timber Systems Division added: “We are delighted to celebrate our anniversary, and it is testament to the hard work and dedication of our team over the past 25 years. Many employees that started with us in the beginning are still with us today and will have witnessed a great deal of change and progression in that time. To mark the occasion, all employees signed a JJI-Joist that was produced on the day of the anniversary, and it will be displayed inside the building.”
Source: www.jamesjones.co.uk
NHS buildings to meet future needs and a major focus on reducing waste by active planning.
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UK INDUSTRY NEWS
Kier Secures HMP Channings Wood Contract
Kier has been appointed by the Ministry of Justice (MoJ) to deliver an expansion to HMP Channings Wood, a Category C men’s prison near Newton Abbot in Devon. This is the latest award for Kier to either build a new prison or expand an existing prison in the UK and will adopt an offsite approach.
The expansion at HMP Channings Wood will create an additional 494 prison places and will include the delivery of two new fully electric, energy-efficient X-shaped T60 houseblocks that support the MoJ’s continued commitment to reducing carbon emissions through efficient design.
The T60 houseblocks at Channings Wood are the latest iteration of the design that Kier has been appointed to deliver. This work includes fifteen houseblocks across the MoJ estate, following the successful build at HMP Five Wells (pictured) and ongoing projects at HMP Millsike, HMP Elmley and HMP Bullingdon. The houseblocks will be created using modern methods of construction (MMC), with components manufactured offsite.
Kier will also build a workshop at HMP Channings Wood to equip prisoners with the skills and support they need to aid rehabilitation and reduce reoffending.
Bouygues UK Appointed Lead Contractor for Stanmore College
Bouygues UK has been appointed by the Department for Education to build Stanmore College, a further education college in Harrow, under the CF21 Framework. The college will be funded by the DfE’s Further Education Improvement Programme. Bouygues UK will be reconfiguring the college’s existing site by replacing four buildings with four newbuilds, to be completed in summer 2027 with work starting imminently.
Bouygues UK will be using its education building standardised ‘kit of parts’ approach for the build, incorporating net zero principles. This will help ensure flexibility, affordability, sustainability, reduced ongoing maintenance and surety of price and programme. As construction of the college commences, the contractor will be inducting its first cohort of T Level students into Design Surveying and Planning internships, developed in collaboration with the social enterprise, Class Of Your Own, renowned for its award-winning ‘Design Engineer Construct!’ learning programme which will place future professionals at the heart of its cutting-edge projects.
As part of Kier’s commitment to support local communities, the expansion of HMP Channings Wood will provide jobs for local people, including apprenticeships. It will also provide jobs for prison leavers through Kier’s Making Ground programme, which offers work opportunities in construction to prisoners released on temporary licence.
Stuart Togwell Group Managing Director, Kier Construction said: “Kier is proud to be supporting the Justice projects across the UK. We are delighted to be delivering the expansion at HMP Channings Wood in partnership with the Ministry of Justice, where
we will use our extensive experience to deliver this project efficiently and sustainably.”
The expansion of HMP Channings Wood is part of the Accelerated Houseblocks Delivery Programme (AHDP) alliance contract which has been awarded to Kier and Wates. The alliance was procured via the Crown Commercial Service (CCS) Framework, with Kier awarded the expansion projects at HMPs Bullingdon and Elmley, where construction work is currently underway.
Source: www.kier.co.uk
Phillippa Prongué, MD for London and the South East at Bouygues UK said: “We are thrilled to have been chosen for this project, as the education sector is a significant focus area for us, and excited to welcome our T Level interns who will be able to gain an unparalleled understanding of contractor work. Our construction methods for schools have evolved in line with the DfE’s output specification and we are looking forward to using our kit-of-parts approach and incorporating more offsite construction. We know that the construction of high-quality education buildings plays a key role in producing better student outcomes.”
Stanmore College Principal, Annette Cast added: “We are committed to delivering education with immeasurable benefits for our students, both now and for future generations. We are excited to offer them modern, sustainable, state-of-the-art facilities in brand-new buildings that will provide an enhanced learning environment. These new spaces will significantly enrich the student experience, leading to better educational outcomes and equipping our students with the skills and knowledge they need to thrive in their future careers.”
Source: www.bouygues-uk.com
Willmott Dixon to Build Passivhaus Student Village for Staffs University
Willmott Dixon will be the construction delivery partner for Staffordshire University’s new Student Village being built on its main Stoke-on-Trent campus, which is due for completion in 2026.
The development received planning permission in March and Willmott Dixon is set to start on-site imminently. The contractor has been appointed by Staffordshire Campus Living for an improved student residential offering as part of the scheme. Staffordshire Campus Living is a consortium formed by Hochtief PPP Solutions UK and Ireland, Willmott Dixon, Plenary, Pinnacle Group and Staffordshire University.
Dan Doyle, operations director at Willmott Dixon, said: “This new Student Village at Staffordshire University is a significant investment in the student experience. What’s exciting is how it has been designed to blend contemporary sustainable architecture with nature in a unique natural setting.
“We will be incorporating modern methods of construction (MMC) and offsite manufacturing to ensure it is a low-carbon development. Combine this with renewable energy sources, building to Passivhaus design principles and structures that are
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UK INDUSTRY NEWS
directly inspired by the setting, the University will have a development with a strong character and identity –fostering a sense of place and community. Offering a safe, secure, and inclusive environment, students can expect a true home from home.”
Designed by Corstorphine & Wright, FIRA and Ramboll, the village will provide 700 new student rooms in a mix of cluster blocks and townhouses. It includes the refurbishment of the Clarice Cliff Court accommodation that will improve its energy efficiency by 250% through new low-energy solutions.
Professor Martin Jones, Vice-Chancellor and Chief Executive of the University, said: “Providing an excellent student experience is a strategic priority and the Student Village is designed to respond to what students say they want. With the full backing of our Board of Governors, we are delighted to
move closer towards making a start on this project which, alongside our academic course offering and exceptional support services, will help to make us stand out in the market.”
Demolition of existing student accommodation on the university’s Leek Road site following the completion of the Student Village will make way for accessible parkland, which will result in a project biodiversity net gain of 12%. The Student Village also includes a net-zero carbon in operation ‘hub’, which will provide individual and group study areas, flexible use space, and an outdoor seating area on the rooftop terrace. A new pedestrian bridge and boardwalk will link the new accommodation and ‘hub’ with the university’s wider Leek Road site.
Source: www.willmottdixon.co.uk
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UK INDUSTRY NEWS
New BSI Pathway to Net Zero
BSI has launched a new scheme to aid organisations in their transition to net zero, following the publication of research identifying a lack of clarity and guidance as a key barrier preventing many from reaching their net zero targets on time and within budget and in alignment with the UK government’s 2050 net zero emissions target.
The Net Zero Pathway provides a transparent and consistent approach using international standards and guidelines published by ISO. It follows the key principles of the ISO Net Zero Guidelines (IWA42:2022) and is backed up with formal data verification and ongoing audits to help organizations overcome the barriers that are preventing them from reaching their net zero objectives.
The Pathway, published by business standards and improvement company BSI, uses an organisation’s verified carbon footprint data, carbon reduction plans and consideration of planned business growth to evaluate whether targets are realistic, achievable and will deliver net zero by 2050 or sooner.
The scheme will be conducted over three phases, including an initial optional discovery workshop to help companies get ready to calculate their carbon footprint, including scope 3 emissions. Then the organisation’s carbon footprint is verified against the requirements of the quantification and reporting of greenhouse gas (GHG) emissions standard (ISO 14064-1). This ensures that reduction targets are set against an accurate baseline which has been independently verified to ensure all relevant emissions have been considered, thus ensuring an accurate reading on an organization’s journey to becoming net zero. Finally, the business can implement its carbon reduction plans and BSI audit these against the key principles of the ISO Net Zero Guidelines (IWA 42:2022). Throughout this process BSI can provide other gap assessments, training, or certifications such as Energy Management (ISO 50001) as part of the process of getting to net zero.
The proliferation of various products and tools related to net zero has led to confusion in the marketplace due to the absence of a common approach, with research from BSI’s Net Zero Barometer 2024 showing that for 23% of organizations a lack of clarity on what net zero means and guidance on how to take action is hindering progress.
BSI’s research found that while the majority of organisations (83%) are committed to achieving the UK’s legally binding net zero emissions target, 92% say barriers remain in place preventing action. Gaps in internal skills and knowledge were also preventing organizations from knowing how to take action (19%) and only 15% said they were clear on how the offsetting market operates, suggesting an enduring knowledge gap in the overall understanding on how organisations can take action.
Matt Page, Managing Director UK & Ireland, Assurance, BSI said: “BSI’s own research demonstrates that the appetite to reach net zero by 2050 is there, yet nine in ten say barriers remain in place preventing organisations from taking action. Helping organisations to understand both where they are on this journey, and what that transition means for them, their supply chain and their stakeholders, can help bridge that gap and ultimately build societal confidence in the progress being made.
“The Net Zero Pathway is an independent process that ensures reduction targets are set against an accurate baseline that has been verified to confirm all relevant emissions have been considered. This is designed to build credibility in an organisation’s journey to becoming and maintaining net zero status, and ultimately accelerate action on the climate transition to benefit people and planet.”
The BSI Net Zero Pathway is an overarching scheme which includes accredited verification against ISO 14064-1 and key elements from the ISO Net Zero Guidelines IWA 42:2022.
Source: www.bsigroup.com
Trimble Brings Streamlined Workflows to OFFSITE EXPO
Trimble is delighted to once again be exhibiting at OFFSITE EXPO where the technology provider will be showcasing its range of advanced software solutions and streamlined ‘design to manufacture’ workflows for light metal framing and precast concrete.
As well as showcasing its Tekla software tools and features available for the whole design to fabrication workflow, including the Volumetric Modular Tool and Crane Layout Tools available within Tekla Structures, Trimble is proud to also be exhibiting alongside long-standing partner Howick, the light steel-roll forming machinery innovators. With the first iteration of tools offering Howick connections and Howick machine exports developed for Tekla Structures in 2009, there have been several updates since, introducing new components that support light metal framing manufacturers with automated manufacturing processes.
Visitors to the Trimble stand will also be able to learn about its full suite of software and hardware solutions underpinning the 'design to manufacture' workflows, including its MEP design and estimation software and project management software, which is focussed on improving collaboration, field operations and data capture.
Craig Johnson, Field Sales Representative - New Accounts at Trimble spoke about the upcoming event, saying: “We’re very excited to be returning to OFFSITE EXPO for another year. It’s such a key date in the construction calendar and a great opportunity to showcase how our range of software, tools and features can support detailers and manufacturers with enhanced collaboration, automated manufacturing processes and streamlined workflows from design to manufacture and office to field. Understandably, given the challenges facing the wider industry, collaboration, productivity, waste reduction, accuracy and sustainability are all key factors for today’s offsite construction sector – and we believe our software can facilitate this.”
For more on Trimble and what it will be presenting at OFFSITE EXPO see p42
Source: www.tekla.com/uk
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UK INDUSTRY NEWS
NBS Research Confirms Building Projects Getting Greener
NBS has discovered steady growth in the construction sector’s efforts towards sustainability, showing that the number of net zero projects and those achieving environmental targets is on the rise. The 'green gains' were found in NBS’ Sustainable Futures Report, in association with Royal Institute of British Architects (RIBA).
Now in its fourth iteration, it shows the number of net zero projects being commissioned is increasing. Six in ten industry professionals (64%) have worked on a net zero project in the past year – a sign of the sector's growing focus on low-carbon construction. This is compared with around half of all respondents in 2022 (49%).
The study, which surveyed almost 600 people working within the built environment, aims to understand sustainability attitudes and protocols in the construction sector. Since launching in 2022, it has provided an industry benchmark for evolving views and opinions, shaping best practice guides on the journey to net zero. Figures on the number of people who had ‘accomplished sustainability’ were also included. 43% or around four in ten said they had been successful (vs a third back in 2022). Interestingly, this sentiment was felt most strongly amongst clients but was slightly lower for architects (35%).
In addition to reducing the sector’s environmental impact, these stats could show that target-based construction is making a difference. This is alongside other factors such as product availability, and the
increasing use of building product data – which is crucial for architects to ascertain the ‘greenest’ product or material.
However, despite the optimism, barriers to sustainability persist. The primary reason is now cost, whereas in previous years it was due to a lack of client demand. This is unsurprising given recent external forces such as a stagnating economy, cost of living crisis, and price surges for building products and materials. Though clients are clearly starting to see the downstream value of sustainable assets, which is also backed up by the increase in certification to BREEAM within the commercial sector.
Another notable difference is the number of organisations measuring their carbon footprint. Seven in ten firms now measure emissions (70%) compared with just five in ten (54%). Those setting carbon reduction goals have also risen by fourteen percent (76% up from 62%) as did the number of companies choosing to offset carbon. Over half of firms now have carbon offsetting strategies in place (53%) while in 2021 this figure was much lower, at just over a third (38%).
There were also some surprises in terms of the sustainability ‘priorities list’. ‘Embodied carbon’ ranked fourth, with ‘net zero operational carbon’ taking the top spot. However, this is likely due to legislation covering operational efficiency but not embodied carbon. When asked to rank the importance of the life cycle analysis stages from environmental product declarations, embodied carbon took first place.
The report also touched on the role manufacturers play in helping architects achieve low-carbon outcomes. Nine in ten (93%) agreed that robust specification is important for achieving sustainable outcomes. Within that, nearly all architects (94%) agree that manufacturers should supply digital information on the green credentials of their products to boost their chances of specification.
Dr Lee Jones, Head of Sustainability at Byggfakta Group, NBS’ parent company, said: “The construction industry's green momentum is building, with NBS reporting a small boost in net zero projects and environmental targets being met. These are welcome figures and show that, whilst much more must be done, the sector is progressively aiming for a sustainable future.
“Certainly, I’d expect to see new significance given to areas like sustainable land use and biodiversity, especially given the recent introduction of new legislation as part of the 2021 Environment Act. Going forward, I would like to see legislation around net zero building practices going further, covering embodied carbon as well as operational efficiency. For the industry to truly achieve sustainable outcomes, it needs the Government to take a stronger lead, supporting with policy and incentives.”
To download the NBS Sustainable Futures Report 2024 visit: www.thenbs.com
UK INDUSTRY NEWS
Carpenter Oak Acquires Xylotek
Carpenter Oak Build Ltd, award-winning designers and makers of timber framed buildings has announced the acquisition of Xylotek. The acquisition levels up Carpenter Oak Build’s scalability for international growth in timber construction.
With the support of leading independent business advisory practice, ReSolve, the agreement was finalised in July. Xylotek was founded in 2018 by Directors Charley Brentnall (who passed away earlier this year), Oscar Emanuel and Martin Self, with the aim of bringing together their diverse experience and shared passion for wood, to serve projects seeking high ambition for the application of timber in architecture. Operating internationally, the company’s team comprises experts in architecture and timber design engineering, with extensive experience in timber construction.
In 2022, the Company achieved considerable success from various projects, including the ABBA Voyage arena in London, winning industry awards and subsequently doubling its turnover in 2023. Rapid growth led to working capital challenges which had knock-on effects in performance.
Driven by a shared passion for blending traditional construction techniques with contemporary design expertise, the acquisition levels up Carpenter
Oak’s scalability for international growth in timber construction and preserves the future of a valuable timber specialist. The acquisition comes as architects and developers shift towards more sustainable building materials and practices, with timber emerging as a frontrunner for its low-carbon, renewable properties.
Luke Copley-Wilkins, Managing Director at Carpenter Oak Build, commented: “Xylotek has a unique proposition, serving an important gap in the UK construction market. Many leading architects, engineers and clients want to build from wood to decarbonise the built environment and for aesthetic reasons, but prior to Xylotek there was a noticeable lack of suitable expertise in the supply chain. Xylotek filled that gap, and we are pleased that we will be able to preserve that skill and expertise to enhance our offer to customers.”
Carpenter Oak was founded in 1987 and pioneered the building of new structures developed from understanding of traditional green oak construction techniques gained through the renovation of historic buildings. Subsequently, the firm has built hundreds of timber-framed buildings and cultural projects, becoming the UK leader in the new emergence of timber construction based on traditional techniques.
The move combines the experience of Carpenter Oak’s 30-year history in traditional timber construction with Xylotek’s expertise in the design and fabrication of modern engineered timber structures. The pairing of the two companies within the Carpenter Oak Group creates a unique capability to combine deep understanding of wood as a material, with cuttingedge design and fabrication technologies.
Source: www.carpenteroak.com www.xylotek.co.uk
UK INDUSTRY NEWS
Call for Policy Reform for Green Belt Sites
A national planning and development consultancy has called for the Labour government’s review of national planning policy guidance to provide clarity to local planning authorities (LPAs) on how they can develop tailored local policies to support investment and growth at developed sites within the Green Belt.
Following Chancellor Rachel Reeves’ announcement regarding Green Belt development, Lichfields highlights the potential economic and social benefits of planning reform. In new research it refers to the inherent challenges posed by current national Green Belt policy guidance that could stifle, or at least delay, investment and undermine the ability for existing businesses to improve their facilities, remain competitive and continue delivering a range of important services.
The ‘Major Developed Sites in the Green Belt – The Land That Policy Forgot?’ report reveals that a portion of the Green Belt, which includes approximately 12.6% of England’s land area, is developed for a range of uses including leisure and tourism with theme parks and other major attractions, education, medical institutions, business parks, transport infrastructure etc. Lichfields explains that pre-2012 national policy used to recognise many of these locations as Major Developed Sites (MDS) and provided clearer guidance on how LPAs should assess development proposals, but this was removed by the 2012 National Planning Policy Framework (NPPF). This established more subjective, generalised guidance, stripping out the detail around how an LPA could approach the identification, definition and guidance of development at such sites in local plans, potentially limiting the ability of these sites to evolve and contribute to local economies and services.
Ian York (pictured) a Planning Director at Lichfields and co-author of the report, said: “Our research shows that the majority of LPAs are adopting generalised policies that repeat national guidance. We must move away from a one-size-fits-all approach and adopt local, bespoke policies that recognise the unique characteristics of these sites. The report urges LPAs to engage with landowners and operators to create detailed policies that clearly define development parameters, ensuring these sites can thrive without compromising Green Belt integrity.”
The research shows that of the 180 LPAs with Green Belt land, only a third have adopted criteria-based, bespoke policies, while two-thirds default to generic NPPF guidelines. This local policy context means less certainty for owners and operators to plan for the future of their sites where there is a continuous need, in the case of theme parks and leisure attractions for example, to renew and refresh attractions and overnight accommodation to ensure they remain attractive to visitors and competitive.
Furthermore, there’s a regional disparity in the policy approach, with the North West of England having the highest reliance on generic NPPF-based Green Belt policies and the South East of England leading in bespoke policies. York added: “National Government has a very important part to play. With the new Labour government’s commitment to update the NPPF within its first 100 days, there is a crucial opportunity to reintroduce policy guidance akin to the previous MDS framework. This will provide much-needed clarity and support for LPAs and developers alike.”
You can download the research in full at: https://lichfields.uk/content/insights/majordeveloped-sites-in-the-green-belt
Bullivant Supply Precast System for Persimmon
Roger Bullivant is proud to announce its collaboration with Persimmon Homes East Scotland on a multiphase housing development project located at Pirnhall Road, Bannockburn, Stirling. Utilising the innovative RBeam foundation system, capable of pairing with any pile type, ensures this project can adapt to diverse ground conditions, highlighting RBL’s commitment to versatile and reliable construction solutions.
This development will encompass the construction of 104 houses and two blocks of flats, with the first phase supporting 19 detached and semi-detached homes. The project will utilise approximately 840 piles across its entirety, with the first phase requiring a combination of 140mm driven steel tubular piles and 200mm driven precast concrete piles.
The combination of steel and precast piles was chosen based on the specific geological characteristics of the site. Shallow rock presence on selected plots, less than 3m deep, necessitates the use of steel piles to efficiently drive into the shallow rock strata, while precast piles are utilised where deeper penetration into the made ground overlying soft to firm gravelly clay is required. This ensures optimal stability and performance of the foundation system across varying ground conditions.
The precast RBeam system's unique capability to pair with any type of pile makes it an ideal solution for the diverse ground conditions encountered at the development site. The initial phase will see the installation of just over 880 linear metres of RBeam, out of a total of 3200 linear metres planned for the entire site. This first phase, completed in just eight weeks, showcases our efficiency and expertise in foundation engineering.
Mark McAllister, Foundation Systems Discipline Manager for RBL’s Scotland Region, stated: "The flexibility of the RBeam system allows us to effectively address the unique ground conditions at the Stirling site. By pairing the RBeam with both steel and precast piles, we can ensure stable and reliable foundations for the diverse range of homes being constructed.”
Source: www.roger-bullivant.co.uk
UK INDUSTRY NEWS
NG Bailey Wins University of Suffolk
M&E Services Contract
NG Bailey has secured a seven-year contract to provide maintenance services to the University of Suffolk. The contract will see NG Bailey providing a full range of mechanical and electrical (M&E) maintenance for the University of Suffolk’s main campus, located on the Ipswich Waterfront.
The latest win builds on the company’s significant expertise in delivering facilities services in the education sector, with NG Bailey providing ongoing maintenance and repairs, as well as supporting new projects across the University’s 18,000sq m of lecture halls, laboratories, offices, catering and student breakout rooms and social spaces. The contract will be managed by a local team with extensive knowledge of providing M&E services for educational facilities, with plans to bring fresh talent onto the project from the business’ apprenticeship programme and graduate scheme.
Sarah Hotchen, Managing Director at NG Bailey Facilities Services, said: “Our Services division has a long track-record of engineering excellence and intelligent building management in the education sector, and we’re delighted to be expanding our capabilities further in this area. The University of
LHC Welcomes New Era of Procurement Product Innovation
As part of its ongoing growth strategy and continued investment in people, public sector construction framework provider LHC Procurement Group (LHC) has bolstered its team with a new Director of Product Innovation.
Shona Snow joins the company having spent over 20 years in procurement – the last 11 of which have been in the public sector. As a chartered member
Suffolk is a dynamic workplace, with an emphasis on sustainability which aligns with our own values at NG Bailey. We’re excited to embark on this journey to contribute to the growth and success of the University, aiding it in achieving its own long-term vision and strategies as a socially responsible institution.”
Nigel Lucker, Director of Estate and Facilities, at University of Suffolk, commented: “We are delighted to be partnering with NG Bailey as our mechanical and electrical service partner. Our Estate Strategy aims to fulfil our vision that whatever our students’ study with us, they will do it in state-of-the-art surroundings. We maintain exceptional spaces and create a more sustainable future through working with
of the Chartered Institute of Procurement & Supply (CIPS), Shona has led several complex collaborative procurement projects across local authorities including Surrey County Council and Southwark Council.
It was during her time as a procurement consultant for Southwark Council that she first encountered LHC. She worked closely with LHC’s regional team on the development of the Architect Design Services (ADS1.1) framework. Upon completion of her contract, Shona was employed directly by LHC as a consultant before providing maternity cover for the then-Regional Director of LHC Jennifer Castle.
Jennifer, who is now the Group’s Chief Operating Officer, said: “Shona impressed me so much that I trusted her to deliver the strategic vision for LHC London and the South East, working alongside the acting director, in my absence. She has a ‘think outside the box’ mentality, which she expertly couples with astute practical delivery. I’m really pleased she has joined us as the new Director of Product Innovation.”
As well as a wealth of experience, Shona brings a genuine passion for making a difference, which is what drove her to transition from the private to public sector in 2013. “I moved into the public sector because I wanted to have a win-win relationship with my supply base and work for an organisation that saw suppliers as its allies, with whom they could work
our partners, and the team at NG Bailey have shown they share our vision and values that will support our overall aims.
“Over the past five years, we have invested across our campus to create environments that showcase the latest teaching methods and support our students to achieve great things. We are delighted to have a partner that understands who we are, and how we wish to enhance the staff and student experience, walking alongside us as we create and maintain exceptional buildings.”
Source: www.ngbailey.com/services
together for the good of the taxpayer,” says Shona. “I felt that, in the public sector, I could be perfectly positioned to support progress and drive change during my career.
“I’ve always been inspired by LHC’s purpose-driven ethos, and the fact that it’s not for profit really appeals to me. I’m looking forward to properly getting underneath the skin of LHC and using my collaborative working style to draw out innovation and new ideas from the procurement team and wider organisation. A huge passion of mine is removing barriers for SMEs when it comes to being appointed to frameworks, and actively attracting SMEs from more diverse backgrounds. I will therefore champion even more developments in this area.
“My work will help us to better serve the needs of clients as they face ongoing pressure to upgrade and decarbonise their building stock, and keep abreast of regulation and policy changes, all while battling to keep their heads above water financially.”
Clive Feeney, LHC’s Group Managing Director, added: “Shona will not only breathe new life into our frameworks, but she will also be instrumental in helping us to implement our social value strategy. This is going to allow us to have even more of a lasting impact on the communities in which we operate.”
Source: www.lhcprocure.org.uk
UK INDUSTRY NEWS
Taylor Lane Timber Frame Helps With Bristol Regeneration
Taylor Lane Timber Frame has constructed 49 homes using its ‘Classic’ wall system at Shackleton Heights in Lockleaze, Bristol, a development by housing provider Abri. The Hereford-based timber frame manufacturer was appointed by main contractor Speller Metcalfe on the known quality of its services and competitive rate.
Timber frame was the build method of choice for the houses on the site and brick and block work was implemented on the traditional flats. Chloe Burke, Senior Quantity Surveyor at Speller Metcalfe commented: “Timber frame is a quicker construction method than building the houses from traditional masonry. It also allows us to achieve greater airtightness for SAPS and Building Regulations.”
Taylor Lane’s Classic wall system is categorised as MMC Category 2 and includes factory-fitted breather paper, external sheathing and stud insulation. For this scheme Taylor Lane recommended 100mm PIR insulation. Once fitted, the wall system achieves a U-value of 0.19 W/M2K.
Several types of rusticated brick were selected for the external finish. On some house types the brickwork is toothed for added interest. This had to be factored into the timber frame design as the stepped course impacted the cavity depth. Where the toothed
detail occurs, the bricks step out to create a 60mm cavity, ensuring the minimum 50mm clear cavity is maintained.
Sustainability is a focus of the new development, and the use of timber frame is a contributing factor.
Timber is a natural insulator and is the ultimate lowcarbon building material. These advantages, coupled with the air source heat pumps installed throughout the development, lower the carbon footprint of the EPC B rated homes and cut energy bills for residents.
Chloe Burke added: “We have a good working relationship with Taylor Lane and have worked with them on several previous projects.
They responded very quickly to queries and we had a good experience with everyone we dealt with at the company. We were very impressed with their work.”
Shackleton Heights is situated along Crome and Constable Road in the northern suburb of Bristol. The new homes have helped revitalise land that had been derelict for over ten years. The development is part of the wider Lockleaze regeneration project which is seeing over 760 homes being built in the area.
Alongside Speller Metcalfe, Abri employed Emmett Russel Architects, Welling Partnership and Jubb Engineers on the scheme.
Source: www.taylor-lane.co.uk
UK INDUSTRY NEWS
Wiltshire Council Gets Agile with Modular Homes
Agile Property and Homes, in partnership with Wiltshire Council, has submitted a planning application for seven affordable homes at a former brownfield garage site at Ramsbridge Crescent in Salisbury. The proposal is for seven low-carbon affordable homes built using MMC. The homes would be built to Future Homes Standard 2025 and would be very energy efficient, utilising panelised fabric first construction.
The homes would be available to people who are in accommodation that is unsuitable for them and generates a significant cost to the council. One of the properties would also be a two-bedroom home designed for people with disabilities.
Cllr Phil Alford, Wiltshire Council Cabinet Member for Housing, said: “These low-carbon affordable homes to be built using modern methods of construction (MMC) would be one of several developments we are currently progressing and demonstrates the innovative approach we're taking to provide affordable housing for Wiltshire residents who need it as part of our wider vision for 1,000 affordable homes across the county.
“The development is part of our council house build programme, which will see over £200million invested in building new, energy efficient council homes up to 2030. We are also making a substantial investment in improving existing council homes to ensure they achieve a minimum energy performance rating of B.
Thurston Group Forging Ahead
Yorkshire-based offsite construction company, Thurston Group, has revealed its latest financial results, with growth in revenue and pre-tax profit despite challenging market conditions. Headquartered in Wakefield, with additional manufacturing sites in Hull and Catfoss, Thurston Group designs and manufactures modular buildings for sectors including construction, education, healthcare, and nuclear. The group has seen turnover increase by 8%,
Affordable housing is a key aim of our business plan, and this scheme is a clear example of the work we're doing to make it a reality."
Pat Steward, Head of Opportunity, Agile Homes, added: “It’s a perfect setting to demonstrate how much modular housing has progressed, with vastly improved construction methods, use of natural, biobased materials and fantastic thermal performance. As with all of Agile's developments, we're also able to deliver significant social value, by manufacturing panels in prison workshops for example, and massive environmental benefits, such as carbon capture (around 250 tonnes of atmospheric carbon in this development) by using natural materials, a biodiversity net gain of 47% and nutrient neutrality solutions agreed pre-submission. A tribute to team effort."
with revenue growing from £47million in 2022 to £51million for the year ending October 2023. Pre-tax profit also increased to £11.4million from £8.1million the year before.
Under the leadership of Managing Director Matt Goff, who joined in 2018, Thurston Group has experienced impressive year-on-year growth, doubling turnover in the past six years from £24million despite volatility in the construction sector as the industry continues to rebound from the challenges posed by the COVID-19 pandemic with a number of high-profile competitors folding in the past year. The company’s success can be attributed to its stronghold across multiple industry sectors and its ability to capitalise on evolving market dynamics. It has also focused on offering higher-end modular buildings which are typically more permanent, gaining market share in the education and health sectors as well as traction in new markets such as infrastructure, transport and commercial buildings.
With the UK construction sector set for growth following Labour’s changes to planning laws Thurston expects to see further growth, developing their product offering to key supply chain and increasing its partnerships with key targets. “I’m happy to report another year of solid growth,” said Matt Goff, “Our continued success reflects our steadfast dedication
This project utilised a South West Procurement Alliance (SWPA) procurement framework for suppliers who are capable and committed to using low carbon methods when constructing houses.
Penny Searson, Regional Manager, South West Procurement Alliance, said: “We were able to provide a robust and efficient route to market for Wiltshire Council, which has enabled them to secure Agile as their contractor for this project. Our Low Carbon Offsite Housing Construction framework enabled the council to conduct a mini competition, ensuring the best value for money and quality for the delivery of this low-carbon housing development. We are delighted to continue supporting Wiltshire Council with their housing development requirements.”
Source: www.agile.property
to excellence, sustainability, and stakeholder value creation.
“As we embark on the next phase of our journey, we continue to invest in the development of our product and services offering, as well as in our staff, recognising that their skills and expertise are key to our success. We are driving continuous improvement through the modernisation of the business infrastructure and expanding our core product range through in-depth material testing and R&D. With a strong order book and increasing shift to modern methods of construction, motivated by a skills shortage and product performance targets, we are well-positioned for another record year and have an exciting pipeline of opportunities from both repeat and new customers.”
To further underscore its commitment to innovation and staying ahead of the curve, Thurston is investing in a comprehensive brand overhaul. The refresh includes the renaming of its three group divisions to better showcase the variety of products and services Thurston provides, as well as a revamped website that enhances the company's brand identity and market presence.
Source: www.thurstongroup.co.uk
UK INDUSTRY NEWS
Insulated Timber Panels for Skylon
Knauf Insulation products have been used in the bespoke, timber frame wall panels constructed offsite by specialists Taylor Lane to create a ‘living lab’ created for tomorrow’s sustainability engineers at NMITE’s Skylon campus. Created by a cohort of young designers, the campus building is biophilic, an exemplar of advanced timber construction techniques and a ‘living lab’, as well as being an educational space.
NMITE is a higher-education provider that has been created from the ground up by its founders, teachers, donors, and a cohort of young designers. Its goal is to give young people a path to becoming integrated engineers that are ‘sustainability conscious’ and ready to find solutions for achieving net zero. NMITE needed a campus that facilitated its unconventional style of teaching and reflected the aspirations of the institution. Sustainability was an important goal, as was using biophilic design – used to increase the building occupants’ sense of connection to the natural environment.
Knauf Insulation’s products were used for the prefabricated panels supplied for the construction of the building. Taylor Lane built 20 panels using a selection of non-standard materials and techniques specified by NMITE to demonstrate different approaches to students. Although each panel was
unique, they all had a 240mm cavity that was insulated with OmniFit® Slab 35. The insulated panels were then craned into position before being attached to the building. Some were attached to the cross laminated timber (CLT) frame, others to steel, so that students could readily observe even more varied approaches to construction.
OmniFit® Slab 35 is a glass mineral wool slab designed for use in both timber and steel frame constructions. Its thermal conductivity is 0.035 W/mK, and OmniFit® Slabs also provide sound insulation, a crucial feature for a busy workshop and educational space. “We chose OmniFit® Slab 35 for this project for several reasons. Its thermal and acoustic performance was important, but we also knew that, in the spirit of the project, we wanted to use materials that were sustainable.
Glass mineral wool can be made from recycled glass and has low embodied carbon,” explained Knauf Contracts Director, Paul Harris.
The campus building is now home to students of CATT and the Centre for Automated Manufacturing (CAM). NMITE’s vision of an experimental, educational, sustainable, biophilic and functional campus has blossomed, thanks to the work of contractors Speller Metcalfe and Taylor Lane. Knauf Insulation’s OmniFit® Slab 35 has played a small but significant role, providing thermal and acoustic performance using a sustainable material, for an institution dedicated to teaching environmentally conscious engineers.
Source: www.knaufinsulation.co.uk
UK INDUSTRY NEWS
Roofspace Solutions Deliver Affordable Housing in Collaboration with Flagship Homes
Roofspace Solutions has provided their offsite manufactured i-House solution to Flagship Homes’ new development in Great Ellingham, Norfolk. The 60-home development will consist of 30 affordable rent homes, to help people secure stable accommodation, and 30 shared ownership homes, which allows prospective buyers to take their first steps up the property ladder. These homes will be built by Lovell Partnerships, who Roofspace Solutions have previously worked with.
As part of the new development, Roofspace Solutions were selected to provide the i-House full housing shell to all 60 plots, alongside Posi-Joist floor cassettes and roof trusses from their sister company Pasquill. The development features one, two and three bedroom homes, and consists of a mix of 51 detached and semi-detached houses and nine bungalows.
i-House is a housing solution, which provides a full, watertight shell ready to receive roof coverings in just five days. Working with H+H, who provide the Celcon Vertical Wall panels which form the walls of the i-House, build time can be reduced by transporting the panels to site ready-made and craning them into place. H+H Vertical Wall Panels are lightweight, durable and airtight, while offering exceptional thermal and sound insulation. i-House consists of inner leaves of external cavity walls, separating walls, floors, lintels, cavity closures and insulation, making it the perfect solution for housebuilders and developers who are looking to deliver new homes quickly and in volume.
New requirements state that all developments should be designed to accommodate for disabled people who may move into one of the plots in the future. Using design software MiTek Pamir, the Roofspace Solutions design team were able to calculate hoist loads, which are in place to ensure any future tenant or homeowner can fit transfer hoists should they require them to move around.
By selecting i-House, homes can be delivered quickly, safely and in volume, thanks to the offsite manufacturing process involved. On-site, the safety of the workers is increased due to the reduced need to work at height using cranes, with each i-House panel carefully craned into place by a fully qualified operator. The amount of waste produced on-site is much lower compared to using traditional methods of construction and once the i-House installation is completed, follow on trades can come in and complete their work while taking advantage of the time savings generated by using i-House.
Oleg Barsoukov, Senior Delivery Project Manager from Flagship, said: “We’ve really seen the benefits of the off-site construction, and it’s fantastic knowing that the homes are future-proofed and constructed with sustainability in mind. Crown View is a great development and we couldn’t be happier with how it’s come together.”
Trevor Haystead, Regional Operations Director from Lovell Homes, added: “The Flagship Homes development in Great Ellingham will offer 60 affordable rent and shared ownership homes, and it was important to Lovell to ensure that every one of these new homes were delivered to a high quality and standard. Roofspace Solutions’ i-House was a natural fit for the development and is allowing us to build these much-needed homes in less time through the use of Modern Methods of Construction. Crown View is due to complete in spring next year.
Source: www.roofspacesolutions.co.uk
UK INDUSTRY NEWS
Work Completes on Shepshed SEMH School
A brand-new specialist school for pupils with Social, Emotional, and Mental Health (SEMH) needs has completed in Shepshed, Leicestershire, offering facilities for students aged 4-16 from September 2024.
Bowman Academy, which is situated on the former site of St Botolph’s Primary School, located to the east of Shepshed on Loughborough Road, will see pupils benefit from a range of facilities to suit their needs. This includes classroom suites with vinyl areas to support practical learning, a sensory “dark room”, practical teaching spaces including a domestic kitchen, a library, a calming room, and a main hall with a demountable stage.
Pick Everard provided architectural services for main contractor Bowmer + Kirkland, which was procured by the Department for Education (DfE) under the Modern Methods of Construction (MMC1) framework.
“Working on SEND schools is always a privilege, with unique design applications and special consideration for the needs of a diverse range of learning,” said Joe West, Associate at Pick Everard. “Creating an environment that is both functional and comfortable for pupils was central to the aims of the project, which should in turn aid the school in attracting and retaining students in the area.
Funding Boost for SIP Manufacturer
A £1million loan from the Mayor of the Liverpool City Region Steve Rotheram’s Flexible Growth Fund has enabled local company Hemsec Manufacturing Ltd to open a new Structural Insulated Panel (SIP) Manufacturing Hub in Knowsley, creating 25 jobs and helping the city region’s drive to become net zero carbon by 2035.
Hemsec started out in St Helens in 1928 making cork cabinets to store ice for ice-cream makers. After decades of innovation, Hemsec were one of the UK’s first to develop SIP for residential applications at scale in 2007, foreseeing the UK’s need for more energyefficient buildings, and for fast construction using modern methods of construction (MMC).
“The construction technique employed on this project was a fully offsite solution, so thorough sequencing and planning was paramount to ensure all materials were delivered safely and successfully, as well as meeting the highest standards. We’re delighted to have worked alongside Bowmer + Kirkland once again to deliver this fantastic academy for pupils in the area with SEMH needs.”
Driving sustainability initiatives, Bowman Academy’s design includes a ‘fabric-first’ approach, which reduces the energy requirements of the building through measures including high levels of insulation, heat recovery and airtightness. Steve Waldron, Bowmer + Kirkland Contracts Manager, said: “We have been working for the DfE since 2013 and are proud of the 73 schools we have completed, but specialist schools are unique in the enormous difference they make to the pupils and their families. We are delighted to continue our relationship with
Hemsec currently works with local housing associations on the development of low-carbon homes which can be built at speed and cost a fraction of price to heat, helping to appease the housing shortage whilst reducing energy bills significantly for occupants. The £1million loan from the Flexible Growth Fund, the maximum amount available to a single applicant, has enabled Hemsec to create a new manufacturing hub in Huyton in Knowsley, creating 25 new jobs along with two apprenticeships for local people.
Speaking about the loan, Liverpool City Region Mayor Steve Rotheram, who recently officially opened the new plant, said: “This is exactly what our Flexible Growth Fund was created for—empowering local companies to innovate, create jobs, and stay ahead in their field. Hemsec’s new manufacturing hub is not just an investment in their future but in the future of our region, driving forward our ambitions to be a leader in modern, energy efficient construction and helping us on our path to becoming a net zero city region by 2035.”
Cllr Mike Wharton, Cabinet Member for Business, Investment and Trade, said: “The purpose of our Flexible Growth Fund is to provide fast and flexible loans to successful businesses to enable them to grow. Hemsec have long been pioneers in modern methods of construction and this loan will help them to stay at the forefront of this exciting sector and create jobs for local people in the process.”
Pick Everard to deliver another fantastic facility which will improve the lives of so many young people.”
Cllr Deborah Taylor, cabinet member for Children and Families at Leicestershire County Council, added: “It is exciting to see the school completed and we’re looking forward to it opening and welcoming new pupils. The building of Bowman Academy part of a wider program to ensure provision is available to children and young people with special educational needs and disabilities in Leicestershire, as close to their homes as possible. This includes both the building of special schools and creating provision in mainstream schools.” The project at Bowman Academy builds on further work from Pick Everard in Shepshed, following its key role in the £2.5million regeneration of its town centre in March.
Source: www.pickeverard.co.uk
Stephen Painter, Managing Director at Hemsec, said: “The opening of Hemsec’s SIPs Manufacturing Hub represents a transformative moment for the Liverpool City Region and the British manufacturing industry. With the capabilities of this pioneering press machine, we have an unprecedented opportunity to accelerate the construction of much-needed truly affordable social housing, providing safe and sustainable homes for our communities. A fabric-first approach to sustainable buildings is crucial for ensuring the performance of our homes is optimised now and remains for the lifetime of the building, securing longevity in energy efficiency.”
The Flexible Growth Fund was established by the Liverpool City Region Combined Authority with £20million in 2020, offering flexible, low-interest loans that businesses can access quickly and easily, to enable projects to be completed. Managed by River Capital, it is available to small and medium-size enterprises (SMEs) undertaking expansion projects and with the ability to raise 50% in match funding from the private sector. All loans are paid back to the Combined Authority with interest, enabling the money to be reinvested in local businesses.
Source: www.growthplatform.org
ASK THE OFFSITE EXPERTS
In the run up to OFFSITE EXPO 2024, we pooled some comments from some of the Offsite Construction Week Advisory Board on where the world of offsite sits from their individual perspective.
“Offsite Construction Week is a time for reflection, a time to share our successes and discuss the challenges ahead. There can be no greater challenge than global warming and as we look to reduce carbon in construction, we need innovative incentives to help achieve net zero targets. Pre-Manufactured Value (PMV) is becoming a driving force in the specification of offsite technology in public sector projects. This metric essentially plays to the strengths of offsite construction and is without doubt a forward-thinking initiative. But I believe the government is missing a trick by measuring ‘value’ just in terms of a financial calculation and overlooking the cost of environmental impact. By adding sustainability targets into the equation, we can align construction costs with net zero targets to demonstrate economic and environmental best value.”
Jackie Maginnis Chief Executive, MPBA
“I think the most promising thing in the industry today is the move towards a more holistic industrialised approach, and looking at it in context of the right solutions to productively deliver what we need in the most sustainable, cost-effective way, that delivers long term value and outcomes that industry, society and the economy needs. I think OFFSITE EXPO is a good opportunity for the offsite industry to come together and explore what's around the corner, where the best practises are, sharing and acknowledging that everyone needs to grow collaboratively and collectively. Understanding what everyone's doing, what the state-of-the-art is, how everyone's approaching the same challenges, what might be around the corner, it just helps your business to be ahead of the curve.”
Alison Nicholl Head, Constructing Excellence
“I think we’ve started to move past the initial distrust of offsite that we might have seen in the past. The industry has worked very hard at moving away from being defined by temporary buildings, and at demonstrating how they can achieve and surpass the quality of traditional construction. We found that the quality is not a barrier like it used to be, but now the perception of risk lies in the systems around the building development process and in our collective habitual ways of working. So that applies to everyone down the chain, from clients to designers, planners, procurement, insurance and warranty providers, and even inspectors on-site. The perception of risk can be a big barrier to choosing MMC in the first place and that’s what we find with our clients when we design buildings and take that to them as an option. But these aren’t insurmountable risks, so we make it easier for people to trust MMC as construction methodology.”
Anne Daw Head of MMC Delivery, HLM Architects
OFFSITE OPINION
“It's been an incredibly tough couple of years for everybody in the construction sector, regardless of what you're doing. I think the fact the new Government has recognised the need for more housing and brought back housing targets is good. Whether we'll ever meet them is another thing. We've got a huge skills shortage that barely gets mentioned. We’re going to build all these houses, but where’s the people to do that and how are we going train them? There are a few things that could happen with the Government that could align, such as the new agenda with the newly launched Skills England. There's a lot of things that need to happen to get those houses built but it’s undeniable that we desperately need them.”
Gaynor Tennant Founder and Chair, Offsite Alliance
“Steel frame is winning on commercial properties on the basis that we can build faster and for any developer or lending organisation, the benefit is that they can lend the money and get that money back approximately four times faster. If you look at the housing market, we are finding a huge amount of growth. Light steel framing is way faster than traditional methods and it gives you the same standards, if not better. But steel framing really does work very well in that sweet spot from three-storeys upwards. For Offsite Construction Week we will take anyone interested to see one of our sites, because while we fully support and are absolutely immersed in offsite construction, the real value isn't always apparent until you get on-site.”
Ben Towe Group Managing Director, Hadley Group
“The Concrete Industries Decarbonisation Road Map has been around for a few years now and there’s been some excellent progress there. A lot of it focuses on the decarbonisation of cement because that’s one of the main contributors to the embodied carbon of concrete. There’s also the greater use of renewable energy for manufacture, use of lower carbon mixes and innovations, and the precast manufacturers are really focusing and challenging on this as well. We’re lucky in this country, we’ve got a well-established local supply chain for precast concrete, so you can get the benefits of MMC – just in time delivery, high quality control and speed of construction. With concrete offsite solutions, you know it’s reliable, it’s tested and a resilient solution. Those are all important considerations.”
Elaine Toogood Director of Architecture & Sustainable Design, Concrete Centre
“The offsite sector is a hugely positive place to be and after nearly 30 years working in this space it is important to take a pragmatic view of natural market shifts and industry changes. I often refer to the Gartner Hype Cycle – that graphical model of how emerging technologies travel through five distinct phases – technology trigger, peak of inflated expectations, trough of disillusionment, slope of enlightenment and plateau of productivity. After some setbacks for businesses delivering volumetric modular housing, I do feel that we are soon to be climbing a steady ‘slope of enlightenment’. Education and healthcare are packed full of successful offsite projects. The new Labour Government has made broad brush promises to increase housing and although detail is still thin on the ground, the purported 370,000 homes per annum can only be delivered with offsite partners – let’s face it what is the alternative?”
Darren Richards, Managing Director, Cogent Consulting
OFFSITE OPINION
“We are excited about the ambitions of the Government to scale up our housebuilding with targets that have not been met since the postwar building era. The digital kit of parts (d-KoP) will allow designers to develop DfMA / MMC aligned solutions, embedded with manufacturing constraints and limitations from the beginning of projects. Having a common language and geometry will remove the need to redraw designs to suit manufacturer systems late in the design process. This will not only improve how we work together as a sector, but through Government it can also help us to increase the choice and interoperability of MMC solutions, enabling the full benefits of MMC to be realised, including programme savings, increased quality and a reduced environmental impact.”
Katie Rudin Housing & Innovation Director and MMC Advisor, Akerlof
“The full housing process is very complex, from land management right through to regulatory control. But in the middle of all of that, you must have a very well defined, robust, transparent DfMA process to be able to communicate where you are in that planning process. We also need academic monitoring programmes. There is a gap in performance, so we need to build into this academic monitoring. We need efficiency and better trust in engagement with the extremely innovative supply chain. If we can fully understand DfMA and bring all of the partners together to start learning how to work with that process, then we will make a big difference. We have to keep the messages very succinct and clear if we are to get the support and leadership that we desperately need from Government.”
Mike Ormesher
Project Director, Off-Site Homes Alliance (OSHA)
“There are so many areas where both the UK and Ireland offsite sectors can learn from each other. There have been many innovations from the UK already implemented by Irish companies having worked throughout the UK over the years, particularly around digital construction. From an Irish perspective, the Irish Government is very aware of the casualties, in the mainly 3D volumetric residential sector over the last few years in the UK and is conscious of protecting the industry against that. New frameworks are in the process of being designed, with industry involvement in designing them to help safeguard against any similar failings. Because of the nature and size of Ireland, there is both a people and department-led approach between Government and industry in creating a sustainable MMC industry. It is very much a collaborative approach built on trusting and respected relationships.”
Paul Tierney CEO, MMC Ireland
OFFSITE OPINION
“The biggest stumbling block to greater take-up of offsite technology is a reliable pipeline of work, and accreditation for the industry. I would argue that the two things BOS members ask for the most is pipeline and accreditation. Pipeline is key and the Government, with its huge procurement portfolio whether that is defence facilities, hospitals or schools, is helping and could help even more to provide that pipeline that our members need and that offsite manufacturers need. The second thing that could help our sector is more accreditation and certification. Because that underpins our credentials, gives us credibility, pulling power, peace of mind and comfort for those clients who are maybe not fully aware of what's feasible, and what ‘good’ looks like in the offsite construction sector. We're definitely encouraging more accreditation and certification.”
Dirk Vennix CEO, BUILDOFFSITE
FREE FACTORY TOURS
As part of Offsite Construction Week, offsite specialists are opening their doors for architects, contractors, developers, and clients to learn more about their innovative systems and manufacturing processes. clients with an interest in exploring #offsite solutions to take a behind-the-scenes look.
The factory tours and CPD seminars, are taking place at various UK manufacturing facilities throughout September 2024. The factory tours are designed to provide a better understanding of why offsite construction methods are becoming such a popular material within the construction industry. Members of the technical teams will be on hand throughout the visit to answer any questions you have regarding their professional services.
A limited number of late places are still available and are free of charge to attend:
The Advisory Group has curated the topics and nominated speakers for the OFFSITE EXPO Masterclasses programme. Sharing insights from the organisations they represent, their expert recommendations will ensure a highly focused, factual overview of the sector and the challenges it faces. The Advisory Group will act as an unbiased Ambassador for Offsite Construction, ensuring that the key trends and challenges of the industry are addressed during the series of events in September and beyond.
16 September - Coventry
16 September - Leicester
19 September - Worksop
19 September - Derby (Site tour, not factory)
20 September - Braintree
20 September - Merseyside
Bookings are screened by the host company for approval. If you would like to take part or know more information visit: www.offsiteconstructionweek.co.uk to book/enquire.
CREATING A NEW DIGITAL WAVE
Eva Magnisali, Founder & CEO of DataForm Lab, spoke to us about why accelerating the adoption of automation in offsite construction is central to a successful future industry.
Q: With a background in architecture, engineering and robotics, what was your inspiration for creating DataForm Lab and what experiences have you drawn from?
Eva Magnisali (EM): My inspiration for creating DataForm Lab originally stemmed from observing inefficiencies in digital workflows in the AEC industry, particularly the gap between design and manufacturing.
As an architect engineer, I worked on large-scale infrastructure projects using advanced computational tools to create complex designs. However, I quickly realised that designers often create complex models that require significant post-rationalisation to make them manufacturable – a process that is costly, time-consuming and inefficient. This led me to explore automation as a solution to bridge the gap, enabling seamless translation from design to production.
In parallel my decade-long experience programming industrial robotics further shaped my vision. I recognised the immense potential for automation technologies to bring significant benefits in construction, but I also realised the need for critical thinking regarding their application. It became clear to me that automation’s true value is in offsite manufacturing. But my experience taught me that if we want to create long-term value in the AEC industry, we need to apply automation wisely, rather than just following short-term technology trends.
Q: For those unaware, what does the platform offer those operating in the offsite sector in terms of improving design options or thinking about adopting factory automation?
EM: DataForm Lab is a start-up on a mission to transform the AEC industry by accelerating the adoption of automation in offsite construction.
DataForm Lab's software platform is unique in its ability to seamlessly link design and manufacturing for offsite construction.
The platform enables manufacturers to automatically configure projects, and instantly translate designs into production drawings and machine code. Most importantly, design is optimised for manufacturing performance: the design automation process considers the constraints and capabilities of the manufacturing processes. This leads to more efficient and feasible designs.
The platform allows offsite manufacturers to simulate and optimise factory operations through dynamic scheduling. With the factory simulation tool, the operation of existing production lines is optimised using advanced algorithms, considering product variability and dynamic bottlenecks.
DataForm Lab’s platform also helps businesses understand when, how and in what form automation can be integrated into offsite manufacturing, to maximise efficiency and capacity. Offsite manufacturers can create, simulate, and compare automated production line designs instantly, ensuring that integration aligns with both technical and commercial goals.
Q: There are many software tools on the market – some would say too many – what are you offering different and how is DataForm Lab challenging construction industry perceptions about digitalisation and factory automation.
EM: What makes DataForm Lab unique is its seamless integration of design and manufacturing. We're not just another software tool: we’re providing a comprehensive roadmap for automating design and manufacturing,
Project: Circle Square Hotel, Manchester, UK
DIGITALISATION
leading to substantial business-wide impact and long-term success.
With DataForm Lab’s platform, design is optimised for manufacturing performance, and production line operations account for design variations. This creates a continuous feedback loop, significantly enhancing efficiency in offsite manufacturing.
Our solution is tailored specifically for offsite manufacturing, ensuring that every step, from product configuration to manufacturing, is optimised and aligned. A key differentiator is our ability to make real-time adjustments in design and production schedules based on changing conditions, offering unmatched responsiveness. Our mission is to increase capacity in construction by optimising the manufacturing performance of offsite factories. By automating design-tomanufacturing workflows, we make the integration of manufacturing automation a natural and low-risk progression.
Q: The use of digital tools is central to offsite manufacture, with platform approaches, repeatable components and harmonised design – is it inevitable that the future of building design and construction be techdriven?
EM: Yes, I believe that the future of building design and construction is inevitably tech-driven. The key to unlocking its full potential lies in seamlessly integrating design and manufacturing. Without this integration, the benefits remain isolated, and true innovation is stifled.
To significantly increase industry capacity, both design and construction must be technology-driven and operate in a continuous feedback loop. There's also a misconception that offsite construction requires complete design standardisation. This is only necessary when real-time adjustments in design and production information aren’t possible, or when translating design to manufacturing is slow and cumbersome. By automating digital workflows from design to manufacturing, our platform allows for design freedom within manufacturing constraints. We standardise design rules, not outputs, enabling offsite manufacturers to fully leverage their systems’ design flexibility while instantly updating production information, including drawings, bill of materials, and machine code.
Q: Improving productivity is a common concern across the construction sector – how can factorybased manufacture and a more digital approach improve productivity levels?
EM: There are several factors that contribute to low productivity in the construction sector, including the unique nature of each building and the challenging process of translating design into construction terms. Also, the disconnection between design and construction often leads to incomplete, outdated, or inaccurate production information, resulting in inefficiencies, increased costs, and the need for rework.
DataForm Lab addresses these issues by automating the translation of design into production information
for factory-based manufacturing. This approach not only eliminates many inefficiencies, but it also reduces the time required for this translation by 90%. Additionally, it allows design to be optimised for manufacturing performance, ensuring designers are taking into account the constraints and capabilities of the existing manufacturing equipment and processes. This digital approach also means that offsite manufacturers can now optimise their factory operations through dynamic scheduling, planning their production according to the individual customised products that need to be manufactured. This unlocks additional productivity and increases manufacturing performance without the need for capital expenditure.
Q: Decarbonisation is critical across the construction industry generally – how can digital tools address issues surrounding the circular economy, waste reduction and overall sustainability?
EM: Digital tools play a crucial role in advancing sustainability in the construction industry. Digital tools can also improve factory operations. For example, factory simulations can optimise resources utilisation, further decreasing the operational carbon footprint. Additionally, when design and manufacturing are seamlessly linked, offsite manufacturers can efficiently plan and manage their supply chain, supporting a lean, ‘just-in-time’ approach. This reduces inventory costs, enhances overall efficiency, and minimises waste across the supply chain.
DIGITALISATION
In general, by focusing on efficiency and sustainability, digital tools can help manufacturers meet increasing environmental standards. With this in mind, DataForm Lab’s platform offers a comprehensive solution, focusing on improving manufacturing performance, while advancing sustainable practices, and streamlining supply chain management.
Q: The Golden Thread attempts to connect design, manufacturing and delivery with the huge volumes of data generated during a project together – how do you think this data can be used better to prove the benefits of offsite methods?
EM: Leveraging data to enhance offsite construction is at the heart of what we do—it's no coincidence that ‘Data’ is central to our name. In general, the innovative use of data empowers offsite manufacturers to respond in real-time to changes and also: builds strong, data-backed business cases that instil confidence in clients about the advantages of offsite construction, identify design and manufacturing patterns through data analytics, leading to continuous operational improvements. It also captures and analyses factory capacity and availability, allowing for real-time responsiveness when bidding for and taking on new projects. This capability reassures clients with the promise of short lead times and on-time delivery. By effectively using the data generated during a project, offsite manufacturers not only can improve their operations but also prove the tangible benefits of offsite methods to clients and stakeholders.
The UK can benefit from a more integrated approach that aligns design, manufacturing, and delivery processes, ensuring that the offsite industry continues to innovate and meet the evolving demands of the construction sector.
Q: From an international perspective, how do you see the current state of the offsite industry in the UK? What can the UK learn from other global offsite markets?
EM: The UK is a strong player in the global offsite construction industry, benefiting from significant government support and incentives for offsite construction that are significantly advancing the sector. These incentives are crucial and should be strengthened to maintain and expand the UK’s competitive edge. However, there is room for improvement, particularly in automation integration, and collaboration across the supply chain.
There are valuable lessons the UK can learn from other global offsite markets. Countries like Japan, Sweden and the United States have well-established offsite industries, particularly in areas like precision manufacturing, automation and sustainability.
Adopting these best practices can help the UK further enhance its offsite capabilities. Embracing advanced automation, fostering collaboration among stakeholders, and prioritising sustainable building practices will be crucial. Additionally, the UK can benefit from a more integrated approach that aligns design, manufacturing, and delivery processes, ensuring that the offsite industry continues to innovate and meet the evolving demands of the construction sector.
Q: The recent £1.1million of seed funding led by Marathon Venture Capital must have been a real boost – what plans have you for 2025 and how do you see the offsite landscape changing in the next 18 months?
EM: This funding will allow us to expand our team and accelerate our ambitious product roadmap, helping us meet the rapidly growing demand for our innovative platform. DataForm Lab is already being used by some of the most prominent offsite manufacturers worldwide. Our platform, which is both material and sector agnostic, is utilised by manufacturers of 3D and 2D timber and steel systems to successfully complete housing, commercial, educational, and hospitality projects. Looking ahead to 2025, we plan to enhance our platform's capabilities and continue expanding our international market presence. As the offsite industry evolves over the next 18 months, we anticipate increased adoption of digital tools and automation, further driving efficiency and sustainability in construction.
For more information visit: www.dataformlab.com
Images: 01. Eva Magnisali, Founder & CEO, DataForm Lab 02-04. DataForm Lab’s platform helps businesses understand when, how and in what form automation can be integrated into offsite manufacturing to maximise efficiency and capacity
Eva Magnisali will be speaking at OFFSITE EXPO on 17 September during Session 1: Raising the Bar – Creating a Zero-Snag Culture and is a judge for the BOS Innovation Hub Challenge.
PRODUCT INNOVATION
WRAP-AROUND IMPORTANCE
Leading the way for insulation across the offsite sector is Superglass –here they outline some of the important reasons why their products are significantly benefitting a range of businesses.
The building industry is undergoing rapid changes, with the focus now on safety, speed, efficiency and performance. Products and systems fundamental to the design of volumetric modular buildings are changing too, enabling the delivery of high-quality, precision engineered buildings for the future.
Superglass, one of the UK’s leading glass mineral wool insulation manufacturers, is supporting that change by offering an extensive range of glass mineral wool insulation products and after-care service tailored for offsite construction projects, excelling in both product performance and providing an unparalleled level of customer service. Superglass manufactures 100% of its rolls, slabs and batts insulation products in Stirling, focuses on supplying products
for modern methods of construction (MMC) product Categories 1 and 2 –pre-manufacturing 3D and 2D primary structural systems – ideal for the offsite market. The offering is well received by customers, too.
A recent in-depth study conducted by MRA Research revealed that three quarters (76%) of businesses acknowledged that Superglass has significantly benefited their business, and 81% of our customers feel valued by Superglass, a key indicator of success in an industry known for its high customer expectations. The study also revealed that Superglass stands out in the industry, with all customers rating the company as either equal to (42%) or better than (58%) its competitors.
“Superglass insulation, made from up to 84% recycled glass is lightweight and compression packed which minimises both the cost and environmental impact of transportation,” says Tony Gordon, Head of Product Management at Superglass. “Fire safety is a critical feature that we believe should be in-built into every product across the construction supply chain. All Superglass products are deemed noncombustible with a fire classification of Euroclass A1 (the highest possible rating) when tested to BS EN 13501-1 Reaction to Fire. This commitment to safety is integral to not only our ethos, but to the safety of staff on site and the ultimate occupants of the building.
“Superglass glass mineral wool insulation provides effective thermal insulation which in turn maintains a comfortable indoor living environment. Our glass mineral wool insulation's performance remains uncompromised during the offsite assembly process, boasting a thermal conductivity range of 0.044W/mK – 0.032W/mK.
It’s also the ideal choice for modular building methods due to its excellent thermal, acoustic and fire properties.
“Our commitment to sustainability, innovation, and customer service drives us to push the boundaries and continue to deliver for our customers, and ultimately the end user. Once installed, Superglass products can save up to 200 times the energy used in the manufacturing process. The insulation products are backed by an Environmental Product Declaration (EPD) and hold ISO 14001 Environmental Management certification. In addition to thermal benefits, Superglass insulation products provide excellent acoustic performance, a crucial factor in reducing sound transfer between rooms or in party and separating walls between dwellings.
“Versatility, customisation and flexibility are integral for constructing with offsite materials. All Superglass products are inherently flexible and can be easily cut or shaped to fit various spaces. This makes installation simple and quick due to a wide range of thicknesses and product widths, especially if standardisation of components may not always align perfectly with site-specific conditions. Providing flexible, versatile products is important for our customers to purchase with ease.”
For more information visit: www.superglass.co.uk
Images:
01. Superglass insulation is made from up to 84% recycled glass, is lightweight and compression packed to minimise both the cost and environmental impact of transportation
Building sustainable homes and stronger communities.
PRODUCT INNOVATION
CLEVER THINKINGSIMPLE DESIGNS
Dan Westgate, Managing Director of Brilliant Ideas, outlines how their pragmatic approach to innovation in construction has helped produce market leading products.
As an inventor, our Chris Massey has an incredible efficiency for spotting an unmet need on construction sites – and meeting it with a safer, faster, cheaper and greener alternative. Our modular products and systems are based on clever thinking, simple designs and a worldwide application enabling our expansion into Qatar, Greece, Iceland, Belgium, Spain, Angola, Saudi Arabia and Holland.
Our line-up includes load spreader mats, inflatable safety net recovery system, temporary safety hole covers, hollowcore perimeter shuttering, instant pipe shuttering and stadium solutions. With 34 patents to our name, our approach to new product development is pragmatic. We fully embrace that not everything will work but we have an unwavering bravery to push boundaries, to develop multiple prototypes, engage in independent testing and analysis before trialling them in real world conditions.
One of our successful innovations which we’re showcasing at OFFSITE EXPO is ALIMATS®, an interlocking aluminium load spreader system for cranes and powered access. We came up with the idea of developing our own mat modules when the site team working for our sister company Beresford’s experienced daily
frustration working with steel crane mats because there wasn’t a suitable alternative. Steel is strong but it’s also heavy so standing around waiting for a crane to set them up was adding extra time and cost to projects.
The development challenge was finding a material that was strong and resistant to bending, light enough to be picked up by hand and certifiable after repeated use. Our research steered us in the direction of extruded aluminium. By testing multiple profiles our inspiration came from how plastic companies make hollow PVC window ledges, reducing weight but retaining strength – a design we were confident would give us a market advantage.
We’ve continually evolved ALIMATS® since its launch in 2007, to become a leading brand based on its technology. But now our biggest challenge is educating the industry on crane mat materials and how they have a critical bearing on safety and performance. Most competing mat manufacturers still focus on promoting the strength of crane mats, and not the stiffness. Research tells us that the stiffness hierarchy is steel, aluminium, timber, nylon and polyethylene. Plastic mats are still widely used, but the quoted safe working loads are unrealistic. Why would you want plastic mats below
your crane outriggers when it’s proven they bend under load?
ALIMATS® have also been used under temporary cabins for a concert at Hyde Park, propping systems used in the construction of nuclear submarines, rescue equipment during the maintenance of a large attenuation tank, over a suspended floor for large track movers within a nuclear facility and as a 320m long access road on private ground.
Being a successful small enterprise is an undeniable advantage because it gives us the freedom to sidestep internal bureaucracy and rigid protocols that can come with bigger firms, empowering us to enter the market much more quickly. But it’s not just about developing new innovations, we’re always deliberating how to evolve our existing systems which give them their longevity.
For more information visit: www.brilliantideasltd.co.uk
Chris Massey, CEO of Brilliant Ideas has been shortlisted for Pioneer of the Year at the Offsite Awards 2024. Meet the Brilliant ideas team at OFFSITE EXPO on Stand C21.
Images:
01. ALIMATS® interlocked directly under the crane outrigger
02. ALIMATS® configuration under the crane outriggers
MODULAR IS THE ANSWER –WHAT IS THE QUESTION?
Adam Salt, Business Development Manager for A.Proctor Group, assesses expectations around quality in the offsite sector, and the use of measurement techniques as part of wider technical support.
Historic stigmas often hold the construction industry back. The offsite sector has recently suffered the stigma of high-profile companies struggling due to significant financial challenges. It is heartening to also read about success, such as that at Thurston Group, which it reports as being the result of working across multiple sectors and focusing on: “offering higher-end modular buildings which are typically more permanent.”
Look at any offsite manufacturing process – be it the size of the facility, the cleanliness, or the care taken in handling and moving modules – and it is clear we’re talking about something that is, and should be seen as, a quality product. Of course, cost-effectiveness is desirable, and will likely be achieved over time via scale. But the modern offsite industry is still relatively nascent and runs into issues when it tries to scale quickly. All of which makes
1us wonder: is the sector trying to run before it can walk? And does aiming for cheaper hint at a possible misjudgement?
Value engineering and cost saving is a crucial aspect of any business strategy to enhance profitability and remain competitive in the market. Modular and offsite businesses looking to grow in a competitive sector are no different. However, the pursuit of cost savings is not without its risk, and it is important to remember that modular and offsite construction is the answer to our problems.
Beauty is more than skin deep (but first impressions count)
The first meaningful encounter some clients and contractors have with offsite modules is when they’re delivered for installation. Shrinkwrapping and taped-on membrane systems have been the common
approach to protecting manufactured modules, but storage, handling and transportation can all cause damage. The result is modules arriving on-site with plastic wrapping or membranes dangling off and flapping around in the wind. Presentation is key. People want to see something good and instead are presented with a terrible visual that doesn’t represent the quality of the product being handed over.
We’ve all received goods in the post where the packaging is damaged and felt the instant worry about the products inside. In the offsite sector those feelings are exacerbated, reflecting the challenge of operating in the sector. Even without bad press to counter, insurance and warranties are harder to obtain. That is compounded by clients making greater demands on modular companies than they would if taking a more ‘traditional’ procurement/construction route.
Wraptite®: a solution that offers more than just protection
Little wonder, then, that companies are going the extra mile to try and avoid negative perceptions. We’re seeing more and more companies using products like our self-adhesive Wraptite® membrane to serve not only as the external air barrier, but also as protection for the module during storage and transport.
Occasionally, companies don’t understand the full range of benefits they get from using Wraptite®. As well as protection, it offers a simplified external airtightness line that eliminates difficult detailing internally around plug sockets, pipe work and other penetrations. It offers vapour permeability and water hold out too. Crucially, it is a solution to making any offsite panel or module a product to be proud of when delivering to clients. Taped-on membrane solutions in construction tend to come unstuck.
PRODUCT INNOVATION
Wraptite® is a self-adhesive membrane with full adhesion to the substrate behind, while preventing moisture passing through or air leaking out.
Using measurement tools when storing completed modules
Quickly reel off the standard list of benefits associated with offsite construction, and it often reads: better quality, reduced labour, less waste, faster installation. Faster delivery and installation, however, can mean modules are manufactured and then stored. In the UK, there are many examples of offsite factories where modules have nowhere to be stored but outside (by contrast, equivalent European operations tend to include indoor space where completed modules can be kept from the elements).
Modules will have moisture that needs to dry out, but shrink-wrapping traps that moisture and can lead to condensation and mould growth in modules. Temporary flat roofs are needed to stop ponding water exerting excessive loads on the modules’ structures. With all this potential exposure to external moisture, as well as trapped moisture needing to dry, the effects of storage on the performance of the finished building need to be understood. To that end, the A.Proctor Group technical team has found their knowledge of moisture movement modelling put to new uses.
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Numerical simulation of moisture movement and condensation risk is defined in BS EN 15026:2023 ‘Hygrothermal performance of building components and building elements. Assessment of moisture transfer by numerical simulation’. The method analyses heat, vapour and moisture transfer through a building element to give an accurate measure of temperature, relative humidity and water content within the element over a specified time period. These calculations are called WUFI® calculations, named for the Wärme Und Feuchte Instationär (translation: heat and moisture transiency) software developed by the Fraunhofer Institute for Building Physics in Germany. The software operates in accordance with BS EN 15026. Our team most commonly uses the WUFI® software to assess moisture risk in solid walled buildings but has also used it to assess the drying out process for volumetric modules, especially where no external insulation has yet been fitted.
Is it time for offsite manufacturers to measure in-service performance?
WUFI® calculations are just one aspect of wide-ranging technical support that we offer to offsite manufacturers. Training presentations and drawing mark-up are some of the services we offer at design stage. We visit factories, make recommendations, and give guidance on which of our membrane products are best suited to the solution being manufactured.
Fundamentally, we like to ask: what are you trying to achieve? What are your challenges? Then we look for the best product to give the answer. Support extends to installation as well, with toolbox talks, hands on training, site visits and reports. All of that can contribute to achieving the best-possible quality on-site. What it can’t do is tell you how a building is performing once in use. That can only come from dedicated performance monitoring and measurement, and meaningful evaluation procedures that take into account occupant feedback.
Knowing how a completed building, delivered via offsite modules, will perform in reality would send a powerful message. It would address any uncertainty, or even mistrust, around the construction method. It would confirm to clients and contractors that they’re receiving a solution with a known level of performance. Such certainty could reduce the number of hoops that manufacturers need to jump through – leading to more orders and those allimportant economies of scale, without compromising quality.
For more information visit: www.proctorgroup.com Images: 01 -03. Wraptite® is a self-adhesive membrane with full adhesion to the substrate behind, while preventing moisture passing through or air leaking out
PRODUCT INNOVATION
DRIVING OFFSITE WITH DIGITAL TECHNOLOGY & DFMA
If offsite holds the key to construction’s future, we must change the way we approach project design. Craig Johnson, Trimble’s Field Sales Representative – New Accounts, describes why a Design for Manufacture and Assembly (DfMA) approach is so vital.
If we are to deliver on the offsite vision, it is essential that it is considered from the very outset of a project. It is well known that the success of any project will often be determined as early on as the initial concept and design phase, with each completed stage in turn influencing and shaping the next. Indeed, the process stretches far before and beyond the final construction and assembly phase. Only if a project is designed, modelled and detailed with offsite manufacturing and assembly in mind, can the value of these modern methods be realised.
Defining DfMA
Defined as a methodology that focuses on simplifying the design of a product or component to improve its ease of manufacture and assembly, structures designed in this way can help to push the well-publicised benefits of offsite even further, from a reduced construction programme time through to improved efficiency and productivity levels on-site. How can you best incorporate DfMA principles on your next offsite project? At its heart is correct first-time products, accurate manufacturing and assembly tolerances, as well as a structure that is designed to be easily assembled. Digital technology is surely the perfect partner, with the benefits and
capabilities of 3D modelling, cloudbased collaborative environments and streamlined data flows from office to field and vice versa, all aligning with the demands and requirements of offsite construction.
DfMA in action
Winner of ‘Infrastructure Project’ in the 2024 UK Tekla Awards, the Gatwick Airport Station upgrade was undertaken to improve the facilities within the station. Specifically addressing issues with overcrowding and improving the passenger experience, it also ensures additional capacity for future growth. It was a critical requirement for the project to try and deliver these works while maintaining near normal operations for the passengers using the station. One of the key components was the expansion of the existing station concourse, which had to be built over the top of four existing live tracks and platforms. This required the maximising of all DfMA opportunities and extensive advance co-ordination with MEPH and Finishes, while also ensuring full integration with existing structures and services.
Kilnbridge Construction Services were tasked with delivering three structures within the scope of works,
collaborating with Costain, Systra, Emico and others to deliver the project successfully. The main overarching challenge on the project was the severe spatial constraints, with virtually every component having to arrive on the project ready for direct installation and the Kilnbridge team having to maximise the amount of work completed on all components offsite. This was achieved in several ways, including:
• Extensive co-ordination and allowance for cladding and MEPH support structures and penetrations, to ensure they were fully integrated at design stage
• Development and integration of connections and interfaces with all balustrades and glazing by third parties
• NC and PDF files for each component were exported directly from Tekla Structures for profiling, cutting and drilling using full CNC operating systems
• Ensuring exact build sequence management
• IFCs for the individual assemblies were used to assess transportation constraints, including swept path analysis and crane lifting operations to ensure weights were compatible with size restrictions.
For more information visit: www.tekla.com/uk
Images: 01-02. The Gatwick Airport Station upgrade was best ‘Infrastructure Project’ at the 2024 UK Tekla Awards
Learn more about the value of Trimble’s digital offering for offsite construction at OFFSITE EXPO - Stand F16
A full panelised system is now possible
New insulation and cladding features
• Visualise and incorporate multiple materials within one model
• Directly integrate information between software and machinery
• Add multiple layers and customise insulation properties
• Fully detail cold-rolled steel, hot-rolled steel, and concrete
Easily perform all these tasks within the same model using the Framing Tools extension in Tekla Structures. Tempted to give it a try?
tek.la/structures-free-trial
PRODUCT INNOVATION
ESSENTIAL SELECTIONS
As the construction industry continues to rapidly evolve, there is significant pressure to rethink building methods to save time and money while boosting sustainability. Knauf have long been central to this drive for change.
One promising solution is the use of modern methods of construction (MMC) and events such as OFFSITE EXPO that are crucial for advancing innovative practices within the industry. OFFSITE EXPO will connect offsite supply chain service and product providers with architects, engineers, consultants, contractors and clients who want to be future-ready.
Knauf’s offsite solutions
Knauf brings value to offsite construction by significantly reducing build times. A prime example is the Knauf ThroughWall system, an all-inone BBA-approved solution featuring steel framing components, internal insulation, plasterboard, external sheathing, and external insulation. This panelised system is designed for easy factory installation, supports various external finishes, and meets stringent fire safety regulations.
A major advantage of Knauf’s offerings is its rigid compliance, countering the misconception that offsite products lack necessary certifications. The ThroughWall system, for example, holds all necessary performance certifications, ensuring regulatory compliance and safety. Additionally, Knauf’s System Performance Warranty provides extra protection when the full system is used.
Knauf’s Airless Finish spray alternative to plaster is an example of how offsite solutions can be beneficial. The ready-mixed spray is quicker to apply and has a shorter drying time than traditional methods, requiring less time on the job and enabling faster project progression.
Knauf’s GIFA Flooring, another innovative product, offers a tongueand-groove interlocking system that eliminates the drying times associated with traditional wet floor screeds, providing an efficient and structurally sound offsite flooring solution.
Sustainable solutions
Knauf will showcase these innovative products and systems at the OFFSITE EXPO. Attendees can visit the Knauf stand to learn about Knauf Airless Finish, GIFA flooring, the ThroughWall system and high-performance plasterboards like the Fire Panel and SoundShield. Already favoured by large-scale offsite construction teams, Knauf continues to support the MMC and offsite construction industry in driving innovation and sustainability. For more information visit: www.knauf.co.uk 1 2 3
Sustainability is a core focus for Knauf, and an advantage of using MMC and offsite building products. The Knauf GIFA flooring system is an alternative to wet screed, while the Knauf readymixed finishes don't require water for mixing, therefore use less water on site. Knauf are committed to reducing their environmental impact, being a responsible business, and acting with future generations in mind. They continue to use recycled content in some of their plastic packaging and offer different logistics options from BioLNG to trains in some areas. Also recognising the importance of skilled labour in MMC and offsite methods, Knauf offers extensive product training
to help contractors quickly and efficiently upskill. This includes training for the Airless Finish, ensuring workers are proficient in the latest offsite construction techniques.
For designers, Knauf’s Planner Suite – System Finder is an online tool that simplifies offsite construction by providing quick access to system data and specifications. Knauf products can be imported into Revit and ArchiCAD for streamlined project design, with options to save products for future use.
Transforming Construction with Knauf’s Offsite Solutions
Accelerating the delivery of building excellence
Experience Knauf’s cutting-edge solutions at Offsite Expo 2024. Knauf’s MMC solutions cut construction time, reduce costs, and contribute to a better built environment, whilst offering a certified performance using exceptional finishes.
Visit the Knauf stand and find out how we’re transforming the face of modern construction.
TRANSPARENCY AND TESTING BUILDS TRUST
Manufacturers have a clear role to play in ensuring a building is specified using safe and sustainable materials. John Mellor, Head of Marketing at UK producer and supply chain partner Glidevale Protect, explains how the company is taking this approach and responsibility seriously.
With offsite projects increasingly being constructed with high premanufactured value (PMV), it’s important specifiers get beneath the surface of product performance claims on the building materials to be used, to understand how they’re verified. Offsite manufactured structural timber buildings are designed to deliver quality construction with high insulation values and good airtightness using a truly sustainable material. The level of thermal performance required to be as energy efficient as possible can be helped with the use of reflective wall membranes both on the cold and warm side of the insulation.
Taking time to reflect on U-values
Thermal resistance (R value) is the key metric to gauge the thermal performance of reflective membranes, but the measured values can vary based on how the material has been tested, for example, testing pre- and post-ageing, the distance of fixing centres used and whether logos have been printed on the surface of the membrane. Small changes to R values can alter the U value for the structure, so it is important to understand which factors have been considered by the membrane manufacturer as part of the calculation.
The current STA Advice Note 18 guidance for external wall breather membranes highlights the need for all manufacturers to clarify and verify technical data provided. This includes data for reflective wall membranes which must be tested to the required thermal and emissivity performance standards, claiming aged surface emissivity (ε) and thermal resistance R value figures (m2K/W) which are fully independently verified by a third party, UKAS accredited certification body.
Glidevale Protect provides aged thermal resistance values on its external and internal reflective membranes to accurately reflect real life performance figures in a worstcase scenario. For example, its own best practice ensures that all thermal resistance results consider any logo printing on the low-emissivity surface and are based on the external membranes being installed with the appropriate maximum horizontal fixing centres of 600mm as recommended in STA Advice Note 18.
No smoke or mirrors
Earlier this year, Glidevale Protect launched a new Class A2-s1, d0 flame retardant external wall breather membrane – Protect FrameSafe FR. Its Class A2 rating exceeds Building Regulations Approved Document B, making it suited for higher risk occupied buildings as defined in the 2022 Building Safety Act.
Reaction to fire testing is an assessed rating of the amount of protection a construction membrane will offer against the development of a fire. It’s important to understand the scope and integrity of any fire rated membrane testing. Has the product has been tested free-hanging and as part of a system in an end-use application? Has it been assessed
on different substrates and using appropriate fixings? Was a tape used as part of a system? When was the test carried out – if it was more than three years ago this can impact on the validity of the result.
Tests were carried out on Protect FrameSafe FR by an independent laboratory, both free-hanging and also mechanically fixed to two different substrates with a minimum density of 37.5kg/m3 which were tested separately: a Class A1 rock fibre insulation substrate and a low-density Class A2 fire board. The A2 reaction to fire result was the same in all cases, demonstrating that it will perform just as well in-situ in the same field of application.
And although it’s not a requirement of the current Building Regulations to test the specialist tape used to seal the laps of the membrane, Glidevale Protect also included its Protect FR ancillary tape as part of its independent fire testing certification for Protect FrameSafe FR. It’s another way to ensure the testing was realistic and accurate.
Trust is everything and membrane suppliers should be able to easily provide a full breakdown of how their products have been tested and any limitations of use so you know you can rely on the integrity of the product being specified, giving transparency to building owners and end clients that the installed products are fit for purpose and aligned to technical performance claims. For
Providing the foresight for offsite...
Our offsite construction product solutions and expertise help us to meet your future design and build requirements for façade and flooring applications.
• Bespoke and adaptable products make stunning designs possible
• Easy and quick installation
• Technical advice and support
• Simple and safe to transport
• Robust and adaptable onsite
• UK manufacture/supply
• A1 Non-combustible fire-rated boards
NET ZERO PARTNERS
Greencore Homes has chosen Xpedeon as their ERP Partner to help them drive further efficiencies as they continue to design and build homes that are better than net zero and climate positive places.
Most housebuilders define net zero only in terms of operational carbon and energy efficiency. Greencore Homes goes further than that and builds timber homes that are ultra-low total embodied carbon in construction, net zero in operation, and better than net zero embodied carbon in the structure of each home.
With significant investment from shareholders, strong relationships with partners and an experienced senior leadership team, Greencore Homes has ambitious targets to build 10,000 homes that are better than net zero by 2035.
“Xpedeon was really easy for me to understand. I like that data can be manipulated just like in Excel without needing to extract it. This saves a lot of time by allowing you to run a report and get exactly what you need, rather than manually updating a spreadsheet each time. I'm also excited about the system’s features, such as the Mobile App for site staff and AutoInvoicing, which will streamline our purchase ledger process.”
Chloe, Greencore Homes
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“The use of the procurement portal, reconciliation, order placing, and payment was a key consideration for us. We are expecting Xpedeon to be timesaving compared to other systems by reducing admin work and duplication. We have an opportunity to engage with suppliers and subcontractors early enough in a slight change of approach because we do not have an existing process that would mean significant change.”
Iain, Greencore Homes
Why Xpedeon
Following an exhaustive evaluation, Greencore chose Xpedeon as their preferred construction ERP software. Several key factors influenced their decision, such as:
• Easy to use
• Versatility for both office and on-site use
• Detailed analysis of overhead costs
• Dashboards linked to KPI’s
• Clear and easy to produce reporting, with multiple ways to analyse data
• Accurate and up to date information
• Reduced administration and duplication of effort
• Removal of unnecessary manual data input/amendment
• The ability to scale Xpedeon's usage over time
• Seamless and robust approval process
• The Procurement Workbench for its easy-to-interpret summary of key information and quick drill-down capability.
For more information visit: www.xpedeon.com
Images:
01-02. Xpedeon are helping Greencore Homes push their sustainability levels to new heights
“The CVR came across as very straightforward, very quick to run and the reporting is clear and easy to understand. The document control, tendering, and the ability to turn this straight into an order was also a highlight. This is far more efficient for surveyors and came across very well controlled with the right procedures in place that align with and ensure compliance with our QMS processes.”
Emily, Greencore Homes
LIGHT STEEL FRAME
A NEW LEAF IN OFFSITE DELIVERY
Frameclad is launching its Lightweight Engineered Adjustable Frame (LEAF) system at OFFSITE EXPO – what’s involved and how will it change the face of light steel frame design?
LEAF is an adaptable solution developed by Frameclad that is simple in form yet revolutionary in application. A finalist in the 2024 Offsite Awards in the Product Innovation category, the four-axis adjustable light steel frame infill system can be extended and aligned in all directions to overcome the challenges associated with mainframe dimensional discrepancies.
LEAF is the result of the total Frameclad team – designers, engineers, manufacturers and technical experts – coming together to create a system that overcomes an issue that is frequently experienced once a light steel frame infill system arrives on-site.
The surrounding structure in which a frame is placed is not always aligned as intended, and it is important for frames to be as adaptable as possible
to ‘fill’ the void. This issue is particularly relevant for exterior infill walling applications, where concrete can be mis-poured and adjacent structures may be deflected from the intended design.
In a class of its own Patent pending, LEAF is a unique innovation. As an exterior high performance infill walling system, it is typically designed to resist wind loads and is engineered to take a wide spectrum of external cladding systems. For interior infill walling applications, LEAF can be engineered to meet design briefs and Building Regulations for fire resistance, thermal and acoustic insulation. In either application, the LEAF infill system can allow flexibility for the sill and head of the window or door to be adjusted as necessary to be level.
“Firstly, I have to say that we are delighted to reach the finals of the Offsite Awards,” said Nik Teagle, Joint Managing Director for Frameclad. “It is testament to our ‘fit first time’ approach which was the motivation behind this product innovation.
“What sets LEAF infill panels apart is that the system can be adjusted on-site in all directions with total ease. From ‘top to bottom and side to side’ without the use of any specialist tools, cutting or welding equipment. When the aperture is totally ‘infilled’ from ceiling to floor and wall to wall, the innovated light steel mechanism is just locked into place.”
Advancing offsite technology
With the option of A1 non-combustible boards and glass mineral wool insulation, LEAF can be designed and tested to meet fire safety regulations
LIGHT STEEL FRAME
so can be used in high-rise buildings over 18m. With zero waste in the manufacturing process and no cutting or welding on-site, the LEAF system has a predicted design life of 250 years in a warm frame environment. At the end of life it can be adapted, reused or recycled.
“Advancing the development and reputation of offsite technology, our product innovation will increase the wider market opportunities for light steel infill frames by offering assurances to installers and contractors,” adds Nik. “Safeguarding our ‘fit first time’ ethos, LEAF offers installers the flexibility to compensate for dimensional issues. Ensuring that the aperture is totally infilled, improves airtightness within the building envelope to enhance thermal performance and help achieve net zero goals.”
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Saving a vast amount of time when compared to traditional on-site stick built steel frame system infill methods, LEAF has the flexibility to ensure that the project parameters such as datum levels and windows sizes are met. This in turn reduces costs and enhances building schedules as well as reducing
A NEW ERA OF LIGHT STEEL SOLUTIONS
Operating from two adjacent high-tech manufacturing facilities with a combined area of 50,000sq ft, Frameclad has made substantial investment in cold roll-forming machinery, supported by customised Tekla software, to produce one of the largest ranges of steel sections available in the UK today from a single manufacturer. Frameclad draws on experienced technical know-how and a 14-strong in-house team of outstanding designers and engineers.
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health and safety risks by removing cutting and hot works from the construction process. LEAF is backed by ISO and BOPAS Accreditation, NHBC /SCI Infill, CE Certification and Constructionline Gold.
For more information visit: www.frameclad.com
Images: 01-03. LEAF is a four-axis adjustable light steel frame infill system, that can be extended and aligned in all directions. It will be unveiled at OFFSITE EXPO 2024
You can learn more about LEAF and Frameclad by seeing us at OFFSITE EXPO Stand B5.
LIGHT STEEL FRAME
PARTNERS IN STEEL
LGSF are specialist providers of light steel frame solutions and work with a range of clients to provide the latest in quality panelised and volumetric building design.
LGSF has been providing solutions in steel for over 30 years. The familyowned business began at Sherburn Forge in a small village on the south side of the Vale of Pickering, north of the Yorkshire Wolds. Managing Director, Lee Cade founded Sherburn Forge, designing and fabricating architectural railings, small fabrication works and maintenance works.
The business quickly expanded and began working within the M&E sector, and in 2006 launched Modular Plantrooms to satisfy the growing requirements of the industry, designing and fabricating bespoke plantrooms, access platforms, Unistrut modules and services risers – along with specialist and bespoke structural steelwork.
As a natural progression, the business expanded into the production of cold rolled framing, in 2008 LGSF was formed to offer cold rolled steel solutions generally for the construction sector, offering modular buildings,
supplying pre-panelised 3D units, pre-assembled panels and selfassembly sections to modular builders, and building contractors.
Manufacturing takes place at our facilities in North Yorkshire. Producing cold formed steel and hot rolled steel and fabrication, we combine traditional fabrication processes with modern manufacturing processes to provide clients with high quality ‘solutions in steel. We will deliver to your assembly line for further fitting or direct to the construction site.
Our talented and experienced engineering team work with your architect and project team, to design modular steel systems to suit your specific requirements. Any technical queries will be answered and 2D and 3D drawings produced.
High quality pre-galvanised structural steel is used to manufacture load bearing modular frames which provide excellent buildability for quick
construction. Modular builders and contractors rely on us to provide a reliable source of high-quality pregalvanised light gauge steel frames that are ideal for major house building projects. Our frames are accurate and consistent in size and quality, providing the structural integrity required for volume housing projects.
Our pre-assembled steel frames are built offsite prior to delivery to the building contractor for on-site erection or supplied as a volumetric unit. Our pre-panelised 3D units are ideal when speed is of the essence and space is limited. We manufacture and build the modules in our factory. We can then either send the modules to you to factory finish (insulation, cladding, utilities) or alternatively we transport the modules direct to the construction site.
The business now has capacity to roll over 10 million metres of steel and assemble over 2.5million square metres of panel every year. Some of this steel is dedicated to housebuilding, with LGSF having the capacity to roll steel for over 15,000 homes for people every year.
For more information visit: www.lgsf.co.uk
The health of the occupants starts with the health of the building
LIGHT STEEL FRAME
OPTIMAL OFFSITE
With cost concerns ever present across the construction sector, Chair of the Light Steel Frame Association (LSFA) Ben Towe, underlines the economic gains of using light steel frame.
Everyone knows that construction is a tough business. The risks are high and although budgets are often in the millions – profit margins are slim, and it does not take much to tip over into a loss-making position. The positive economic impact of light steel frame construction cannot therefore be overlooked. With its powerful combination of safety, strength and affordability, it is a cost-effective choice for many construction projects across all sectors. Robust, reusable, recyclable and adaptable – steel also has excellent circular construction credentials. As a material it is strong and durable, as a structural framing system it is lightweight and costefficient, and I believe that light steel frame is the most advanced material in the offsite construction portfolio.
Ideal construction material
Light gauge steel refers to the process of feeding steel coils or blanks through a cold forming process. Using precision cut rolls to form the geometric shapes, lengths are cut to size using automated machinery. Then simultaneously or as a secondary
operation, features can be added such as slots and bolt holes for example, to form accurate profiles such as U or C (wall studs and tracks) which can be joined together using screws, bolts or rivets. This method creates strong, lightweight frames ideal for use in various structures including residential buildings, commercial complexes, education and healthcare facilities. Compared to heavier forms of construction, steel framing offers significant advantages both economically and structurally.
Steel frames are especially well-suited for meeting the rigorous requirements of the Buildings Safety Act (BSA) because they are non-combustible and do not add to the fire load of a building. No onsite welding is required during installation, so there is low risk associated with incorrect assembly or fire hazards during construction. These are major considerations and demonstrate why light steel frame infill and loadbearing systems are often favoured to create high-rise buildings over 18m where safety and speed of construction is of paramount concern.
Attractive price point
Not only are they lighter allowing for easier transportation and fitting onsite, but within the context of the whole building cost, the price point is also generally lower making light steel an economic option. A major advantage of using light steel framing is its strength-to-weight ratio, reducing concrete foundation requirements, cutting carbon and lowering costs.
The metal components are designed to be extremely tough and stable, meaning they can withstand high loads with minimal deformation over time reducing inspection and maintenance costs.
The frame assembles quickly and easily on-site and this reduces labour costs significantly. As a result, light steel framing solutions offer greater economic benefits than conventional building materials such as timber or concrete blockwork.
In addition to being strong and economical, light steel frames also provide excellent thermal insulation properties as thermal bridging is
LIGHT STEEL FRAME
eliminated during the design process delivering excellent standards of building performance. This means that heat transfer from outside sources is kept at a minimum while internal temperatures remain constant throughout different seasons – an important benefit to avoid overheating as temperatures rise during the summer months. The frames have exceptional acoustic performance which makes them suitable for use in areas where noise pollution needs to be reduced or eliminated altogether.
Construction finance can be expensive and whilst the recent Bank of England interest rate cut was welcome, the building programme duration is critical to costs. It is the speed of construction delivered using steel framed panels or modules that can dramatically decrease the programme schedule. Reducing the borrowing period can
LSFA – JOIN US
dramatically cut the interest paid and total project costs.
The LSFA and our members will be out in force at OFFSITE EXPO on a mission to explain lots more about what we do and promote the circularity, sustainability and cost benefits of light steel.
The Light Steel Frame Association (LSFA) works to drive engagement, champion change, and spread the word about the cost, productivity, performance and sustainability benefits of contemporary light steel systems. Trusted and widely specified by the UK construction industry – highly innovative and digitally savvy, the light steel sector has developed panelised and modular solutions that deliver high quality buildings on fast-track construction programmes. Bringing together a wealth of experience and technical know-how, the LSFA represents manufacturers, installers, industry supply chains, architects, engineers, consultants and clients operating in the light steel sector.
For more information visit: www.lsf-association.co.uk
Images:
01. Ben Towe, Chair of the LSFA
02. The LSFA will be available throughout OFFSITE EXPO
03. Precision manufactured through a cold forming process
04. Light steel frame – cost-effective construction
As sponsors of OFFSITE EXPO, the LSFA will have a high-profile presence at the event. Presenting in the Masterclass Seminar programme and a major showcase in the specialist exhibition, members will also be taking centre stage at the OFFSITE AWARDS in the Best Use of Steel category. To find out more about the benefits light steel frame can bring to your project or how membership can offer access to numerous high-value opportunities, go to: OFFSITE EXPO Stand E09.
LIGHT STEEL FRAME FLYING HIGH WITH LSF
A brand new six-storey apartment block at the Abbey Wall development in Merton, London, has been constructed over a third faster than traditional methods thanks to a light steel frame system.
Constructed in just 25 weeks by RJB Interiors on behalf of main developer, Indigo Scott, the mixed-use residential scheme comprises 66 apartments and a commercial unit to the ground floor. A typical concrete frame project of this size would likely run to a 30week programme to install the frame, followed by a further 10 weeks of exterior wall construction. In contrast, the Intrastack solution was installed fully in just 25 weeks.
Due to the six-storeys and composite concrete floor, a lighter, more versatile structure was required to support the construction. The developer opted for Intrastack’s light gauge steel system. Not only was it able to provide the right strength and weight-bearing capacity for the apartment construction, but it also enabled the team to speed up the build programme to deliver a quicker return on investment.
An efficient and cost-effective programme
Critical to the project’s success was the ability to manufacture the steel
frame offsite, using a ‘just-in-time’ approach to help improve build times and eliminate on-site fabrication. This process was carefully co-ordinated with planned delivery sequences to complement the build programme and ensure a seamless installation process.
“We pride ourselves in delivering an efficient and cost-effective programme for our clients,” says Matthew Kirby, Commercial Director from RJB Interiors. “The combination of the speed of construction on-site, alongside a high quality, durable endproduct from Intrastack has enabled us to deliver an overall cost saving to our client. We spent approximately 15 weeks less on-site than would have been required with a concrete frame construction. This clearly translates into labour and plant cost savings, estimated to be in the region of £60,000.
“Fabricating the panels offsite in a quality, process-driven manufacturing environment has helped to reduce health and safety concerns. With no cutting or fabrication required on-site, we were able to reduce site preliminaries and plant costs, with rapid construction of the primary structure, allowing us to commence on site activities much earlier than with a traditional construction.
“In particular, the offsite manufacturing techniques meant that waste was handled in a controlled environment, and we had confidence that any offcuts would be either reused or recycled. This is a significant benefit on-site, and we estimate that waste was reduced by as much as 50%, plus the associated time of processing and managing waste disposals. Much of the build also took place during the winter months with exposure to the British weather. The steel frame is less dependent on-site and weather conditions during construction than traditional methods and has enabled a greater productivity rate on-site.”
The Intrastack solution is designed to provide the full primary structure in multi-occupancy buildings; it is delivered pre-panelised to site for installation to create the finished loadbearing structure. According to the Steel Construction Institute (SCI), a key benefit of this type of light steel frame construction system is that foundation loads and sizes are reduced by over 70% relative to concrete and blockwork construction.
Accurate & long-lasting solution
Accuracy of the finished structure was to within just a couple of millimetres. Combined with the average lifespan of a steel framed building with warm wall construction, which can be as
LIGHT STEEL FRAME
much as 250 years, the overall result is a high-quality, durable solution. Indigo Scott is committed to improving its sustainability credentials across each construction project. In doing so the business prioritises thermal performance and is dedicated to reducing on-site waste to reduce the overall carbon footprint.
This meant the Intrastack steel frame system was a natural choice due to its high level of thermal insulation and airtightness. When it comes to light steel framing and modular construction, embodied carbon in the building fabric is reduced by 20% and site waste is virtually eliminated – this is a huge feat compared to the average 10% wastage that occurs when using traditional materials and methods.
Building on investment
Intrastack has invested over £250,000 on comprehensive system testing to ensure each suite of products meets all building performance requirements. By combining steel frame construction with a concrete floor, the buildings acoustic performance is enhanced, and the tested fire performance offers 120 minutes of protection.
For more information visit: www.intrastack.co.uk 3 2 4
Matthew Grant, Technical Product Manager from Intrastack said: “We provide a complete ‘through the wall’ offer, comprising the internal and
external boards, composite concrete floors, and insulation. From the initial concept drawings, we have worked with RJB and Indigo Scott to construct a durable, high performance steel frame system that would meet their needs for speed of construction, improved on-site safety and a reduction in build costs.”
Images: 01-04. The Abbey Wall development has used light gauge steel frame to deliver many cost and time savings
SUPERIOR PERFORMANCE & UK RELIABILITY
The comprehensive construction membrane portfolio of Don & Low offers modern answers to performance and durability challenges of timber frame, steel frame and modular construction.
Meeting the ever-evolving requirements of national standards and regulations in the most convenient and reliable ways has grown to be of paramount importance in the modern construction industry. However, there’s much more at stake than just achieving regulatory compliance. Looking beyond strict numbers, it’s all about responsibly securing our sustainable future while also providing people with structures and spaces that are safe, comfortable and contribute to their wellbeing.
Don & Low, the vertically integrated UK manufacturer, offers a broad construction membrane portfolio engineered to perform and built to last. Made in the UK, at the company’s cutting-edge Forfar manufacturing facilities, Reflectashield®, Vapour TX® Thermo, FrameTX®, Frameshield® and FloorTX® FCM are ideal for timber frame, steel frame and modular buildups, ensuring enhanced performance and longevity.
Reflectashield® & Vapour TX® Thermo When it comes to optimising thermal performance, Don & Low’s innovative duo of reflective membranes can be paired to provide the ultimate solution. Reflectashield® is a walling membrane for the cold side of the insulation, featuring a highly reflective aluminium foil lamination. Effectively aiding
in BS5250 and Part L compliance, Reflectashield® offers excellent thermal resistance of 0.81m2K/W while its low vapour resistance helps in mitigating the risk of interstitial condensation.
VapourTX® Thermo is an advanced vapour control layer (VCL) with a highly reflective aluminium foil lamination, designed to optimise thermal efficiency across floors, walls and ceilings. VapourTX® Thermo has an excellent thermal resistance of 0.79m2K/W, and when placed on the warm side of the insulation acts as an airtight barrier, reducing the risk of condensation build-up and ensuring compliance with BS5250 and Part L.
FrameTX® offers W1 class water holdout and is available in a variety of colours with bespoke print.
Frameshield®
Frameshield® is a high-performance air and vapour permeable breather membrane. It is stabilised against UV degradation and provides effective protection during the building process against wind driven rain, moisture, snow and dust.
FloorTX® FCM
For more information visit: www.donlow.co.uk 1 2 3
Both Don & Low’s reflective membranes are coated to ensure aluminium foil is resistant to corrosion and damage, boast high nail tear and tensile properties, and are independently, third party-certified by BM TRADA to ensure their performance. Plus, Don & Low’s Reflective Tape serves as a reliable repair solution in case of membrane damage during installation and on-site exposure.
FrameTX®
FrameTX® is an air-tight, vapour permeable walling membrane for use as temporary protection for timber and steel frames against the elements.
Thanks to its excellent resistance to water penetration, FloorTX® FCM offers temporary protection for the structure from wind-driven rain and snow whilst remaining vapour permeable to minimise condensation forming at the edge of the floor cassettes and junction with the wall panels. Additionally, sealing FloorTX® FCM to the air and vapour barrier on the wall panels provides air tightness to the intersection between the floor cassette and walls.
Images:
01. Reflectashield® installed on the cold side of the insulation
02. VapourTX® Thermo installed on the warm side of the insulation
03. Don & Low’s manufacturing facilities, Forfar
It’s a Wrap.
When it comes to maximising thermal performance, look no further. Don & Low’s reflective membranes are the ultimate solution. Reflectashield®, a reflective breather membrane for the cold side, and VapourTX® Thermo, a reflective vapour control layer for the warm side of the insulation, work together to enhance energy efficiency and ensure lasting durability in timber frame, steel frame and modular build-ups.
REDEFINING WINDOW INSTALLATION EFFICIENCY
In the fast-paced world of construction, where time and cost efficiency are paramount, Eurocell has introduced a game-changing solution with its InSite system.
Designed specifically for timber frame and light gauge steel buildings, InSite revolutionises the installation of windows, offering unprecedented benefits that reshape traditional construction practices.
Efficiency and innovation
At the heart of the InSite system lies innovation that is aimed at simplifying and accelerating the construction process. By integrating specialist components such as hinges, sealants, cavity barriers, and Eurocell’s acclaimed Logik or Modus window profiles directly into wall panels during factory production, InSite eliminates the complexities of on-site window fitting. This not only reduces labour costs but also minimises on-site disruption, allowing other trades to commence work promptly without the hindrance of scaffolding or unfinished exteriors.
Safety and compliance
For more information visit: www.eurocell.co.uk call: 0870 120 3003 or email: newbuild@eurocell.co.uk 1 2 3
Beyond efficiency, InSite sets a new standard for safety and compliance in construction. It is the first window system for timber frames to undergo rigorous testing to prevent the spread of fire and smoke according to NHBC guidelines. This certification ensures that buildings are not only structurally
sound but also meet stringent safety regulations from day one.
Enhanced site safety and security
InSite prioritises site safety by eliminating the need for working at height during window installation. By facilitating internal completion of cladding and boarding, the system reduces manual handling and minimises the risk of theft or damage associated with separate window deliveries and on-site storage. This streamlined approach not only enhances security but also improves logistics, making the construction site safer and more efficient.
Technical excellence
Technical specifications of the InSite system underscore its engineering prowess. Capable of accommodating window sizes ranging from 320mm to 2800mm in width and height and boasting impressive U-values of 0.9 with Logik and 0.8 with Modus profiles, InSite ensures superior thermal efficiency and performance. Tested by Warrington Fire to prevent fire and smoke spread, and compliant with British Standards for air, water, and wind pressure resistance, InSite stands as a testament to Eurocell’s commitment to quality and innovation.
InSite in action
The impact of InSite is evident in realworld applications. Recently employed at a Places for People project, InSite demonstrated substantial time savings and efficiency improvements. During the construction of terraced houses in Stratton, Inverness, InSite slashed installation times from weeks to a mere two days, effortlessly meeting stringent project timelines and budgetary requirements.
As construction practices evolve, Eurocell remains at the forefront with solutions like InSite. For builders, architects, and developers looking to enhance efficiency, ensure compliance, and elevate safety standards, InSite offers a transformative approach to window installation.
Images: 01-03. InSite is designed specifically for timber frame and light gauge steel buildings and eliminates the need for working at height during window installation
FABRICATE WINDOWS FOR THE INSITE SYSTEM
PANELS IN THE FACTORY
Welcome to the InSite window system from Eurocell. Designed to be fitted offsite. There’s no on-site window fitting. No delays. Fewer operatives needed. It’s the only window system suitable for timber frame that has been fully tested to prevent the spread of fire and smoke from, or to, the cavity. And meets NHBC guidelines. It’s weatherproof the same day, so interior trades can get working straight away. The future’s InSite.
FORMULA FOR THE FUTURE
Following an investment of over £10million, Donaldson Timber Systems (DTS) has increased capacity and boosted technical capabilities at its Witney facility to create a state-of-the-art manufacturing process.
Over the last four years, the UK’s leading UK offsite timber frame manufacturer has responded to market demands by taking timber frame production to a new level. The investment in machinery and performance upgrades at the Witney site in Oxfordshire, includes four stateof-the art timber processing centres and a new floor panel production line offering customers a fully completed pre-glued floor cassette solution. The site has also installed the most advanced automated pre-insulated closed panel wall production line in Europe.
The purpose of the machinery investments is to increase automation to improve efficiency and create additional capacity, reducing the manual labour required and makes operative positions more ‘inclusive’. The new technology also increases the factory’s technical capabilities so more advanced products for offsite
1developments – including the DTS Sigma II timber frame system – can be manufactured to precise specifications with each panel unique – but with the quality assurance industry demands. “A lot of the manual handling challenges have been taken out of equation,” says Witney Factory Manager, Alanna Bowler. “Operatives now have a more ‘machinery minding’ role and that leads to improved accuracy, quality and confidence that panel after panel is going to exit the factory with zero defects.”
Custom-made robotics
Some of the pieces of technology were created specifically for DTS and have never been used before in the industry. Partnering with Randek on much of the machinery development, new techniques, and innovations, DTS ensured current and advanced elements of technology were used, including robotics and laser integration. The increased automation
also reduces the requirements for paper drawings as plans are input digitally, further reducing carbon footprint. “Prefabrication isn't just about constructing buildings, said Ola Lindh, Randek CEO on the Witney developments. “It's about co-creating solutions with our customers, refining their processes, and integrating our technology to drive efficiency and automation. This synergy not only makes housing more affordable but also paves the way for a sustainable future.”
In addition to the internal facility changes – that were set in motion over four years ago – photovoltaic (PV) cells have been installed on the factory roof to produce just under one megawatt of electricity, covering the factory’s own energy needs and an excess of ‘green’ energy that can be exported back into the National Grid for other local businesses and homes to use.
This significantly reduces the site’s environmental footprint and combined with new electric vehicle charging points for staff and visitors, supports DTS’ wider sustainability goals.
The Witney factory installed 2,468 PV cells on the roof and in just over two months. “We have significant environmental ambitions at DTS, including a target of 100% green energy usage by 2030, said Frank O’Reilly, DTS Manufacturing Director. “Adding this 999.54 kWh system to our Witney factory is a huge step forward in meeting this goal. As part of a much larger infrastructure and capability investment at the factory, the surplus green energy we are creating also helps to offset this project.
“The installation of the new machinery in a working factory is unusual for the industry and the process required a phenomenal amount of logistical planning over a period of a couple of years. We’re all proud of the
INNOVATION IN LIFTING
Britlift are a designer and manufacturer of lifting equipment, specialising in the lifting of modular homes, bathroom pods, commercial modules, containerised structures and pre-cast components. With a wealth of experience in the design and manufacture of lifting frames and lifting systems to the Offsite Construction sector, Britlift are the Offsite sector partner of choice.
STRUCTURAL TIMBER
results. We’re creating the capacity and technical capabilities customers require to continue building more advanced and energy-efficient homes and buildings – and futureproofing our own business in the process.
“We’re also excited about what this means for our colleagues, as it is revolutionising the operations process. Now a less physically demanding role, we can hire a wider variety of people to work on-site, helping to plug the current skills gap in construction. We’ve also hired people with an automation background from the automotive and engineering sectors to ensure we upskill our teams and are making the best use of our new capabilities. These efficiencies also provide an opportunity to increase production, creating more positions in time, and allowing us to redeploy people to more value-added roles.”
A home an hour ethos
With about 65% of production catering for the private residential sector and 25% in the affordable area, housing is the clear direction of travel for the panelised products. Adopting a ‘home an hour’ ethos, the design for manufacture and assembly (DfMA) principles are clear to see and compared to the previous production lines – inherited from Stewart Milne Timber Systems in 2021 – the factory is now showcasing serious advanced manufacturing. It is not just about the robotics and the new production lines but about additional Hundegger saws, the PV panels and the new ERP system, to make sure they are primed for industry changes and the next phase of market development across the built environment.
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The Sigma II closed panel timber frame system provides long-term energy efficiency and meets and exceeds Homes England’s minimum requirement for a pre-manufactured Value (PMV) of 57%. The aim is to improve this further with the exploration of factory-fitting cladding and taking brickwork out of the equation – potentially lightweight roof coverings – to propel PMV towards 70+%.
“Timber is the only truly sustainable building material, and we are wellrespected in the industry for the quality of our products,” says Rod Allan, Managing Director of DTS. “But rather than rest on our laurels, we continue to look forward and innovate. We have created the scope to add more capacity and capabilities to the factory
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over time without the need for a largescale overhaul like this one, and we have created a platform for more R&D. It has also made positive changes to our colleagues, as we have seen more people switch to electric vehicles thanks to the free charging points onsite. This is a significant investment but one that will set us and our customers up for continued success in reducing carbon for years to come.”
For more information visit: www.donaldsontimbersystems.com
04. (L-R) Andrew Donaldson, Group CEO, Alanna Bowler, Factory Manager, Frank O'Reilly, Manufacturing Director and Rod Allan, Managing Director of DTS 2
Images: 01-02. The robotics and advanced manufacturing process will increase capacity of the Sigma II closed panel timber frame system
03. DTS facility, Witney
Precision light steel roll-forming and assembly
CPAC Framing brings a specialist service to the construction sector by offering cold formed steel components for frames, walls, floors and trusses. All components are produced to meet our certified I.S. EN 1090-1:2009 + A1:2011 quality standard.
Fully assembled or flat pack 3D volumetric frames and floor cassettes.
• 300 x 65 x 15 x 2.8mm
• Speed tabs eliminate the need for cleats
• 165 and 65mm services holes
• Countersunk 18mm Bolt Holes
Fully assembled 2D Wall panels, infill panels and floor joists/cassettes.
• 15 x 50 x 12 x 1.2-1.6mm
• 34mm service hole
• 13mm bolt hole
• Lip cut and swage
Fully assembled 2D Wall panels, infill panels and Internal partitions
• 89 x 41 x 10 x 1.2mm
• 34mm service hole
• 13mm bolt hole
• Lip cut and swage
A STUDY IN NET ZERO
The term ‘net zero’ is familiar to many but it can mean different things to different people. Mark Brown, Consultant at TG Escapes outlines why it is so important to the education and modular sector.
In the context of the built environment, net zero is used to describe both buildings that are net zero carbon in operation and those that are netzero carbon in their construction. The starting point for a net-zero construction definition is: “when the amount of carbon emissions associated with a building’s product and construction stages up to practical completion is zero or negative, through the use of offsets or the net export of on-site renewable energy.” Likewise, the current definition for a building in use energy is: “when the amount of carbon emissions associated with the building’s operational energy on an annual basis is zero or negative.” Operational energy includes heating and cooling systems, cooking, lighting and plug loads.
Construction energy considers the total carbon emissions created through construction. Only when both elements satisfy a net-zero ideal can a building be deemed to fully comply with the aims of the Climate Change Act and fit within the Government set targets of 2030 for operational netzero and the 2050 embodied target.
embodied carbon materials wherever possible and still ensuring longevity. Efforts should be made to use less materials generally and to reduce the weight of dead loads, thus minimising structural weight and reducing foundation load and size. Transportation to the build site and onsite construction should be reduced by utilising offsite, modular construction. Waste and site works should be minimised, and the construction materials and methods used should allow for future demounting, replacement or reuse of the structure or its elements.
Using timber for schools
timber in construction.” Timber also has some considerable secondary benefits, with biophilic properties helping enhance the learning environment.
Timber classrooms have been proven to reduce stress among students versus traditional classrooms, as evidenced by a 2007 study, Schools without Stress, by Weitzer Parkett and proHolz of Austria. As well as reducing stress, biophilic design can enhance sensory and motor development by using elements from the living, natural environment which can help inspire curiosity, imagination and discovery in students. Furthermore, the use of natural materials can reduce fatigue, while cognitive ability and emotional wellbeing can be increased by the inclusion of nature in learning environments.
For more information visit: www.tgescapes.co.uk 1 2
Where does this all fit into education and modular timber buildings? Natural, sustainable materials should be considered first, avoiding high
As timber is a natural product that sequesters carbon as it grows, it is a highly suitable material for reducing carbon during the product stage. Each square metre of timber frame removes and stores over 12Kg of carbon dioxide during the construction phases. While it is unlikely that the whole build could become negative in terms of carbon just by using a timber frame, it is an essential factor in achieving a calculated net zero build.
The government’s Net Zero Strategy, published in autumn 2021, acknowledges that wood: “has the lowest embodied carbon of any mainstream building material,” and promises to “promote the safe use of
We conduct regular research amongst customers in education to understand how our timber frame buildings perform as classrooms, SEND spaces, studios, early years settings and more. The feedback shows that these ‘natural’ buildings provide spaces which feel very different to other types of buildings. Overall, timber construction will always be more carbon efficient than traditional masonry build. However, as the cost of offsetting rises, the economic case for construction methods that require less offsetting improves. The use of a timber structure makes achieving net zero easier and more economical, which is often the critical factor in the educational market.
CEMENT SET ON MAKING A DIFFERENCE
ECOPlanet Endure low carbon cement offers the perfect combination of eco credentials and great performance.
Low carbon, high strength solution
Fully recognised in British Standards
High levels of sulfate resistance, perfect for below ground works
Proven protection against chloride ingress, corrosion and weathering
Moderate setting time once mixed for easy install
Lighter tone for looks that last
THE MAGNIFICENT SEVEN
Having supplied the offsite sector with premium timber for decades, James Latham know that as housebuilding activity picks up, demand for high quality timber-based panels is set to grow further.
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The UK offsite industry has faceddown tough market conditions over the past couple of years. Low levels of housebuilding have, unsurprisingly, put considerable pressure on manufacturers. Yet the storm clouds are starting to lift.
The new Government has ambitious housebuilding targets at the heart of its agenda and it’s likely offsite will resurge in the residential sector as there is a dash to build new homes quickly, to a high standard. Furthermore, an equally far-reaching public works programme will also see more healthcare, education and penal facilities approved, all growth areas for offsite due to the increasing standardisation of design and build in these vertical.
Ready, willing and able
It’s a developing situation James Latham is watching with keen interest. We know that as activity picks up, demand for high quality timber-based
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panels (one of the most popular product categories amongst offsite manufacturers and developers) will also increase. We’re fully prepared to meet that spike. We also understand the offsite community’s evolving needs, speaking with our customers regularly and continually invest in our products, supply chain and services to offer the ultimate buyer experience. In fact, the recent research, combined with a poll of our 18,000-strong customer database highlighted that it was this holistic proposition which made working with us such an attractive proposition.
Magnificent Seven
If you’re not already convinced, we’ve come up with seven key reasons, to show what sets our products apart from the competition:
• Quality – we only stock the very best panels available on the market, all of which have undergone the most rigorous set of testing requirements before we launch to market
YOUR DISTRIBUTION PARTNER OF CHOICE
As timber-based panels look set to dominate the MMC market in the next five years, we’re positioning ourselves as the distribution partner of choice, providing the highest quality timber, panels, and decorative solutions to help offsite developers get buildings safely on-site, and on time. Give your local Panels Team a call to discuss your next project and how one of our premium boards might feature?
To contact your local James Latham depot visit: www.lathamtimber.co.uk/products/panels
• Variety – James Latham possesses an unrivalled portfolio of the world’s highest-quality, OSB and plywood panels from leading brands including UPM WISA, Garnica, SMARTPLY and Lumin
• Sustainability – all our suppliers are expected to meet our rigorous sustainability criteria, and we aim to stock the highest level of low-carbon/carbon neutral panels available in the UK
• Safety – all our panels are manufactured to the highest safety standards, guaranteeing structural integrity, with a range of specially treated, fire-rated options available on request.
• Consistency – repeatability is an important factor within offsite construction and the panel brands we stock come in a range of standard formats and dimensions which can be duplicated across a standard specification and remain consistent time after time
• Availability – we have a watertight supply chain. Operating nationwide in the UK & Ireland across 12 strategically positioned depots we possess large stock levels which can be quickly drawn of at short notice
• Transparency – all our timber panel products feature in our proprietary carbon calculator, allowing users to see full carbon data on the materials chosen, allowing for informed product selection.
Adding even more value, our in-house team of materials experts can also provide accurate technical support, ensuring offsite developers make the best choice for their project, whatever the scope and scale of the requirement.
Images: 01-02. Timber panels can provide a sleek architectural look
TIMBER = CARBON AND HOUSING SOLUTIONS
Andrew Carpenter, CEO of the Structural Timber Association (STA) believes offsite automation and carbon friendly timber could lead the way in helping Labour achieve its 1.5 million homes target.
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A new Labour government has begun a new era of construction and housebuilding, with the Government committing to 1.5 million homes in the next five years, and in the two months since the General Election this has been the focus of much discussion. The commitment to 300,000 homes per year, is certainly ambitious, but with the right policies and the right systems, it is achievable.
Chancellor of the Exchequer, Rachel Reeves announced that it will reinstate mandatory housing targets for Local Planning Authorities (LPAs) and will open a consultation on a new approach to planning, to support this delivery. It’s a Government that focuses on change, and embracing change is what is needed, and not just by Government.
It is critical that housebuilders, architects and the wider industry look to modern methods of construction (MMC) and offsite timber manufacture to meet the growing housing need, in a sustainable manner. A fundamental change in how we build and deliver homes, how we meet carbon targets and upcoming Future Homes Standard is needed for housebuilding to see real growth.
There is capacity in the structural timber manufacturing sector to deliver 100,000 homes per annum, and the Structural Timber Association believes that this contribution of 33% of the Government’s target would be a major step forward.
While many larger housebuilders have invested and committed to
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building in timber frame, there is a huge opportunity for SMEs to realise the benefits too. From significantly reducing project timescales with faster build speeds, improved quality and reduced waste to saving cost, it’s time to take an in-depth look.
The sector's readiness to achieve these targets is clear from the investment by many manufacturers in greater automation and the first introduction of robotics from Donaldson Timber Systems. Numerous major housebuilders have recognised that the timber industry can deliver valuable benefits and many including Vistry, Taylor Wimpey, Barratt Developments, Cala Homes and Avant Homes are realising and investing in their own factories or establishing long-term partnerships with timber
STRUCTURAL TIMBER
frame manufacturers.
What’s more, boosting production represents a significant economic opportunity – with £10billion gross value already added to the UK’s economy by the timber industry. The sector currently employs more than 300,000 people in 51,000 businesses, and expanding capacity has the potential to unlock many new jobs while also overcoming the skills crisis that has plagued previous attempts to increase housebuilding.
Our industry requires clear actionable policies, policies that put MMC and carbon reduction, and therefore structural timber, at the forefront of supporting Government in the delivery of their housing goals. The policies put in place now will have a significant impact on the UK’s ability to deliver housing targets, great places to live and reducing carbon to achieve net zero. This will be the legacy for decades to come.
Ongoing collaboration across the industry is essential to further increase the market share of timber, which has already grown by 23% over the past three years, with over 198,000 timber frame homes constructed in the last five years. The DEFRA-led Timber in
STRUCTURAL TIMBER ASSOCIATION
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Construction Roadmap, launched late in 2023, has taken root and several projects are now underway to deliver the priority themes including increasing demand, supply and skills.
There is significant confidence from both manufacturers and housebuilders that timber frame delivers our best opportunity to grow the housing market, and now is the time to support
With over 950 members, the STA is the UK’s leading organisation representing the structural timber sector, a sector now valued at over £1billion, and associated supply chain companies. The STA actively work to promote structural timber through innovation and accreditation while raising the bar on quality standards, health and safety, skills training and technical knowledge. Their goal is to drive increased use of MMC and offsite manufacture for the benefit of all stakeholders. Having played a key role in the Government’s Timber in Construction Policy Roadmap development, the STA continues to spearhead its implementation. STA Assure is the STA’s Quality Assurance Scheme that provides confidence in the use of structural timber and member competency and compliance.
the wider housebuilding sector to take the opportunity and transition to timber frame. We are at a key crossroads in construction history with new Government. If we are to address the housing shortage without detrimentally impacting the UK’s ability to meet net zero by 2050, we must embrace change to the way we build. Now is the time for change.
For more information visit: www.timefortimber.org www.structuraltimber.co.uk
Images: 01. Andrew Carpenter, CEO, STA 02. New robotics installed at Donaldson Timber Systems facility, Witney 03-05. Over 198,000 timber frame homes have been constructed in the last five years
SETTING A NEW STANDARD FOR MMC
Over the past year, James Latham has registered a growing appetite across its 12 UK deports for a pioneering engineered timber panel suitable for everything from floors and walls to ceilings and doors.
Plywood is one of the fastest-growing material categories in the UK offsite sector, and within this, WISA-Spruce Special is fast becoming one of the best-trusted products amongst the nation’s modular developers. What sets WISA-Spruce Special apart is that it delivers the full package, in terms of strength, workability, consistency and certification, perfect for an industry that prizes quality, repeatability, and accuracy.
Not only that, WISA-Spruce Special also embodies many of the same, low-carbon values the MMC market aspires to. Ranging from 3 to 13 plies thick, it’s produced from timber from sustainable, certified forests, and manufactured in a low-emission facility.
Don’t just take their word for it, for added verification, we measured the product against our proprietary carbon calculator, a tool that measures the reliability of specific timber’s green credentials against official documentation. WISA-Spruce came out with top marks due to its impressive array of EPDs and accreditations, making it a low CO2 option. This can directly support developers looking to achieve muchcoveted certifications like LEED and BREEAM for projects.
For more information about purchasing WISA-Spruce Special through James Latham visit: www.lathamtimber.co.uk 1 2 3
This is bolstered by its use of WISA’s proprietary ‘Bio-Bond’ adhesive between the plies – replacing 50% of standard glue’s fossil-based phenol with lignin, timber’s inherent bonding agent, reduces the overall carbon footprint by approximately 10%, without compromising technical performance or visual appeal.
Importantly, in an era where occupant welfare is non-negotiable, it’s also a safe product. Structurally robust, it’s suitable for load-bearing applications. That’s not all, it’s also available from James Latham in a Euroclass B FR variant, Wisa Spruce FR. Still not convinced? Then how about its competitive price point? You’d be hard-pressed to find a carbon-neutral panel product of similar performance that provides such value for money.
Widely available throughout our distribution network, plus a directfrom-port option if required for bulk loads, we stock WISA-Spruce Special in volume ready to be called off at a moment’s notice. Short lead times are no problem, as we can get your order of panels to your facility or plant to meet ‘just-in-time’ manufacturing strategies.
Our dedicated panels and specification teams are also on hand for technical support, where you need
them when you need them. This means you can address any WISA-Spruce Special-related query, concern, or request directly with an expert. As you can see, when you order WISASpruce Special through James Latham, you get the full package, from great product through to great customer service, wherever, whenever.
At a time when the modular sector is facing scrutiny regarding quality control issues, knowing you’re working with a panel that ticks all the compliance boxes provides essential peace of mind. Not only that, but it will also give clients, investors, shareholders, and occupants assurance you are dedicated to delivering safe, secure, and sustainable buildings.
Ultimately, WISA-Spruce Special is a product that adds value at every level, setting a new standard for sustainable plywood and supporting a new golden age of MMC.
Images: 01-03. WISA-Spruce Special is bolstered by the proprietary ‘Bio-Bond’ adhesive between the plies – replacing 50% of standard glue’s fossilbased phenol with lignin
The perfect partner for the offsite sector
James Latham is one of the UK and Ireland’s largest independent distributors of timber, panels and decorative surfaces.
With a huge stockholding, solid supply chains and market-leading environmental credentials, we can supply everything you need, from standard construction products to high performing specialist materials
Carbon data available Great service Rapid delivery
In terms of strength, workability, consistency and certification, WISA-Spruce Special is perfect for an industry that prizes quality, repeatability and accuracy.
• Structurally robust
• Dimensionally consistent
• Also available as a Class-B (B-s1,d0 and Bfl-s1) fire rated variant (WISA Spruce FR)
• Fully certified and sustainable
SUSTAINABILITY ASSURANCE
Architects, engineers, contractors and other built environment professionals can now access Environmental Product Declarations (EPD) for the most common timber products with Timber Development UK’s new EPD database.
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If we are to achieve national and international targets to reach net zero carbon emissions by 2050, we need to measure, understand, and significantly reduce the embodied carbon within the buildings and infrastructure we construct. EPD are key for specifiers to design low-carbon assets, helping them accurately assess the impact of their designs and material selections, but historically, limited data has been available.
EPD are essential to achieving net zero in our built environment, helping architects, engineers and other specifiers to make sustainable decisions on material selection as early in the design process as possible. “The timber industry has made significant investments into producing EPD which support designers to make accurate estimates of the whole life carbon of their projects,” says Charlie Law, Sustainability Director, Timber Development UK (TDUK). “This data is increasingly expected by clients and is a requirement for many major developers – particularly on large-scale projects.”
The database provides easy referral to EPDs developed by: UPM, Moelven, Jordeson Timber, Setra, Sodra Wood, Steico, Metsa, Swedish Wood, Vida, James Jones & Sons Limited, Stora
“One of the core missions of Timber Development UK since it was formed is to accelerate a low-carbon future. Together with our members, we are working hard to ensure that our built environment is on track to achieve net zero by 2050,” adds Charlie. “The EPD database follows on from our work at the beginning of this year to make available weighted average embodied carbon figures for 95% of timber supplied in the UK. We are providing all of these data and tools completely free for the use of anyone interested in building sustainably.”
How to use the database: guidance for specifiers
An EPD is a standardised document that provides detailed information about the environmental impacts of a product throughout its lifecycle. It is based on the principles of Life Cycle Assessment (LCA) and follows international standards.
Designers and contractors utilise EPD to evaluate the environmental impacts of various products to be used within a building to develop a building’s
Whole Life Carbon (WLC) Assessment. They can support environmental rules and policies, help inform green building certifications, and facilitate the formulation of more sustainable decisions. These documents can help manufacturers achieve their sustainability objectives, strengthen their position in the market, and cultivate a favourable reputation among stakeholders and customers through meeting market demands by generating credible data. So far, the following products of TDUK members can be found on the EPD database.
• Sawn softwoods
• CLT (cross laminated timber)
• LVL (laminated veneer lumber)
• Glulam (glue laminated timber)
• I-joists
• Softwood plywood
• Hardwood plywood.
The three main values shown on the database are total stored CO2, total CO2e impact excluding biogenic carbon and total CO2e impact including biogenic carbon. Each EPD has a detailed description of the product, including its name, model, and intended use, as well as the name, address, and contact information of the manufacturer.
TDUK encourages everyone within the timber supply chain to provide EPD for their products to allow this database to grow and become the place to find carbon data for timber products.
You can find out more at: www.timberdevelopment.uk/ sustainability/epd-database
Images:
01. Charlie Law, Sustainability Director, TDUK 02. The updated TDUK EPD database will offer a vast range of carbon data for specifiers across the built environment
ACCURATE AND EASY TO USE
Evolution Home & Leisure have taken its previous experience from working in cutting-edge industries such as Formula One, aerospace and car production to hone its vision for housebuilding with thoughts of precision, quality and speed.
In these combined industries they have witnessed innovation and the evolution of manufacturing and development of the highest possible standards in both single focus manufacturing and mass production developing cuttingedge technology to achieve their goals. Combining this knowledge and mindset the founders of the Matrix Panel System have created the Steel Frame Insulated (SFI) Panel, and the potential is endless.
Based in Telford, Shropshire located near the famous Ironbridge, world
renowned for being the birthplace of the Industrial Revolution. Evolution manufacture panels with the detail, accuracy and efficiency of all the above. The panels are designed for all uses, including and not exclusively, quality homes for all sorts of clients including self-builders, councils, social housing, garden rooms, park homes and all types of leisure and offices for commercial clients.
Working with likeminded people from all areas of construction, they have the flexibility in its design process to execute anything that comes its way. The speed of the system creates better opportunities for clients, whether they are self-builders or contractors. Anyone can build its panels and structures with no prior construction experience. Evolution Home & Leisure have simplified the complexity of Formula One and aerospace while maintaining the same levels of accuracy and production.
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Images: 01-02. The speed of the system creates better opportunities for clients, whether they are self-builders or main contractors
MODERN METHOD OF MULTI-STOREY CAR PARK CONSTRUCTION
The number one priority in the design of any structure is the safety of the user. This is no more apparent than in the construction of a multistorey car park (MSCP) where FP McCann have been key providers of precast solutions for many years.
In recent years, there have been a series of high-profile fires, the most recent of which occurred in October 2023 at Luton Airport. The fire which broke out on level three of the terminal carpark caused significant damage not only to the parked cars, but also the structure itself. A partial collapse of the carpark deck resulted in the MSCP having to be fully demolished. The concerning extent of the damage to the steel frame structure, has since given many structural engineers and designers more cause to consider precast concrete not only for key elements such as floors, lift shafts and stair flights, but also for the frame itself.
In the case of multi-storey car parks, the fire resilience of precast concrete is just one of the many benefits. By its open nature, a MSCP is exposed to the elements and is also subject to fuel and oil spills from vehicles. Its anticorrosion properties means that unlike steel frames, no special coatings are required. Where fire sprinkler and M&E systems are specified, precast concrete MSCP’s are designed with pathways for installation. Fast, safe and efficient construction is a major advantage when utilising offsite precast concrete, with build times reduced by as much as 40%.
FP McCann precast concrete multistorey car park structures are designed and manufactured using a precast frame which incorporates several structural elements, including columns, spine beams, spandrels, stairs and lift cores, hollowcore flooring and wall panels. Due to their reduced self-weight, prestressed hollowcore flooring slabs can achieve clear spans of up to 16m – this reduces the requirement for vertical columns, creating better manoeuvrability and therefore reducing the risk of damage to vehicles and the car park’s structure.
The beneficial effects of offsite precast concrete in modern methods of construction (MMC) continues to grow in recognition and developers and contractors alike are turning to this structural system particularly in the case of MSCP’s. Here, we highlight just two of FP McCann’s recent supply and install projects.
For more information visit: www.fpmccann.co.uk 1 2 3
The company has recently completed the supply and installation of a fivelevel precast concrete MSCP at North Manchester General Hospital. If a location ever exemplified the need for safe accessible parking facilities it is a hospital. The 1,000 space MSCP has been built to provide much improved parking facilities.
The MSCP is part of a £25million enabling works package being delivered by national construction and regeneration specialist Morgan Sindall. In this project the largest single span of hollowcore flooring is 15.6m long.
In Poole Dorset, a precast concrete ‘van deck’ superstructure MSCP has been constructed by FP McCann. The four-storey 633 capacity van park has been built to service a major distribution company warehouse. In total over 6,200 tonnes of precast concrete product was delivered and installed. For designers looking to learn lessons from fires like the one at Luton Airport, full frame precast concrete MSCP’s offer an offsite solution which provides not only the programme efficiency benefits synonymous with MMC, but also the peace of mind for users and clients which only concrete can provide.
Images:
01. Precast concrete is key to delivering safe multi-storey car park projects
02. A four-storey van park for a major distribution company warehouse, Poole Dorset
03. North Manchester General Hospital
TUNNEL VISION ON DECARBONISATION
The Silvertown Tunnel linking Silvertown to the Greenwich Peninsula in east London showcases the role precast concrete plays in sustainable infrastructure and low carbon delivery plus can calcined-clays deliver the circular economy solutions of tomorrow?
Precast concrete is the offsite solution of choice when delivering large infrastructure projects, especially those that take us underground. There have been a string of notable projects coming to fruition over the past few years all of which have utilised the intrinsic benefits of precast concrete. Some of the more prominent examples include: Silvertown, Thames Tideway, Elizabeth Line and HS2 Green Tunnels.
Precast concrete is a popular choice for tunnel construction due to several advantageous properties and practical benefits. The big one being quality control. Precast concrete elements
1are designed to meet specific structural requirements and can be manufactured to exact specifications. This precision leads to improved fit and finish, enhancing the overall structural performance of the tunnel. Precast elements are manufactured in a controlled factory environment, ensuring consistent quality and strength. This controlled setting allows for better monitoring of concrete mix, curing conditions, and overall manufacturing processes compared to on-site casting. Factory production has other benefits on efficiency, programme and cost savings as well as health and safety risk reduction
with fewer site-based activities and weather-related delays.
Precast concrete can be customised to meet the unique requirements of a tunnel project. This includes special shapes, sizes, and reinforcement configurations. The flexibility in design allows for innovative engineering solutions tailored to the specific needs of the tunnel, something Banagher Precast Concrete used to deliver a UK first on the Silvertown Tunnel project. The predictability of precast concrete elements in terms of dimensions, strength, and performance ensures fewer surprises during construction. This consistency helps in better planning and execution of the project.
These advantages make precast concrete an efficient, reliable, and cost-effective solution for tunnel construction. The Silvertown Tunnel project in London showcases just some of what can be achieved using precast concrete as the construction method.
Silvertown Tunnel
The Silvertown Tunnel in London is the largest diameter tunnel project undertaken in the UK to date. The twinbore tunnel sits beneath the Thames linking Silvertown to the Greenwich Peninsula in east London. The aim of the project, due to open in 2025, is to help reduce the congestion through the Blackwall Tunnel as well as support public transport links. Infrastructure projects like this are vital to increase the sustainability of major cities like London, here tackling the huge social and environmental issues linked to poor air quality.
The main contractor, Riverlinx JV (Ferrovial, BAM Nuttall, SK Ecoplant), commissioned precast manufacturer, Banagher Precast Concrete, to supply 10,260 segments for the 2.2km of
PRECAST CONCRETE
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tunnels. Banagher worked closely with the client and consulting engineers to deliver the redesigned and intricate precast cross-passage segments, a critical element for the project to remove the requirement for propping during the construction of the cross passages – a UK first.
Banagher also managed to deliver impressive carbon savings of 1,480 tonnes of CO2 on the project. The carbon savings were achieved through incorporating 39% ground granulated blast furnace slag (GGBS) into the concrete mix design and use of steel fibres reduced the impact associated with traditional reinforcement.
KEY FEATURES OF THE SILVERTOWN TUNNEL
Owner: Transport for London
Client: Riverlinx JV (Ferrovial / BAM UK & Ireland / SK ecoplant)
Consultants: COWI and Gall Zeidler
Consultants
10,242 Tunnel Segments
Innovative steel-fibre reinforcement
Concrete mix 39% GGBS
1,480 tonnes of CO2 saved
1,000 trees planted by Banagher ISO 17025 accreditation
potential to divert 1.4 million tonnes of material from potential waste streams if the materials were adopted by the UK construction industry.
Clay is a naturally abundant material in the UK and can offer an alternative to industrial by-products such as GGBS and fly-ash which have been used in projects like Silvertown to lower embodied carbon. UK production of both materials is reducing as the power and steel industries decarbonise, so innovating new approaches is important as the concrete sector moves towards a net zero future.
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Calcined-clay a new light at the end of the tunnel
Using waste clay in cement production could reduce the material’s embodied carbon by up to 30% and boost UK construction’s circular economy, according to a new report. A two-year study led by the Mineral Products Association (MPA) with funding from Innovate UK has demonstrated that UK reclaimed clays and finely ground brick powder can be used as calcined clays in cement and concrete manufacturing to deliver lower emissions compared to the market-leading CEM I cement.
The findings confirmed that calcined clays from these sources have the
An interesting application of this material is being pioneered by the HS2 rail project, which is working on a circular process that involves taking the material excavated by its tunnelboring machines, calcining it on site and then using it as a binder on new infrastructure elements.
By their nature tunnelling and deep excavations generate large volumes of spoil that need to be transported and disposed of creating carbon emissions. By opening up possibilities for repurposing some of this material into a circular process the future of large infrastructure projects could include calcined-clay based supplementary cementitious materials.
For more information visit: www.mpaprecast.org
Images: 01-03. London’s Silvertown Tunnel is the largest diameter tunnel project undertaken in the UK to date. The twin-bore tunnel sits beneath the Thames linking Silvertown to the Greenwich Peninsula
PRECAST CONCRETE TRANSFORMING PRISON DELIVERY
Work is well underway at HMP Fosse Way with Houseblock 8 under assembly, once again proving that precast concrete and offsite manufacture can provide huge dividends for the prison estate.
The new houseblock is set to expand its capacity by 250 prison places and follows specialist provider PCE’s contribution to the successful delivery of the category C resettlement prison in 2021. The company is employing its HybriDfMA Secure Prison system for this project for main contractor Lendlease.
Secure Prison is a hybrid platformDesign for Manufacture and Assembly (p-DfMA) build system and has proven its effectiveness as the blueprint for scalable solutions across the New Prison Programme. Having been utilised in projects such as HMP Five Wells, HMP Fosse Way, in 2023 at HMP Millsike. It has since been selected for the expansion of HMP Elmley, and HMP Bullingdon, and once again at HMP Fosse Way.
Through its p-DfMA methodology, PCE’s Secure Prison system’s ‘kitof-parts’ is optimised for quality, efficiency, and repeatability. Bespoke moulds ensure predictable precision, meaning components are not only more sustainable, using 12% lower embodied carbon concrete mixes, they maintain a consistent high-quality finish throughout. This not only looks good and performs well, but it also enables direct direction, negating the need for excess materials such as plasterboard.
The repeatable ‘kit of parts’ include precast floor/ceiling units, sandwich panels with integrated windows, corridor walls with cast-in cell door frames, internal walls, columns, stairs, landings, and parapets. Components have constituent parts integrated throughout production, including structural ties, builders-work openings, and encased M&E sub-assemblies.
With the majority of operations conducted offsite, quality and safety are heightened, while the number of on-site operatives, deliveries, waste, and resources required are significantly reduced. This streamlined approach allows a small crew to build each houseblock within a 12-week window. With installers, finishers, supervisors and crane drivers, PCE provides a turnkey assembly solution.
Logistics play a crucial role throughout the installation period. Ynomia, a digital asset tracking and information system, creates a digital twin of the design model, tracking every component from factory to final location in real-time. This transparency enables just-in-time deliveries and supports adherence to stringent delivery strategies.
By adopting PCE's HybriDfMA solution, the installation of HMP Fosse Way’s new T60 houseblock unlocks the benefits of repeatable, predictable, and reliable construction, ensuring the final structural solution is completed efficiently, with safety, quality, speed, and value. Using its unique supply chain model, PCE enjoy the flexibility to hand pick the most appropriate suppliers from across the UK and
Europe, ensuring the right product is used for the right solution. The T60 and supporting ancillary units will see over 1,700 PCE components manufactured offsite by five different specialists across a 26-week period. In addition, nearly 8,000 free issue castings are integrated throughout the offsite solution.
Across the New Prison Programme (NPP), there is a major focus on rehabilitation. From influencing the design of prisons, through to the manufacturing and installation of components, efforts are taken to encourage and promote rehabilitation in a bid to reduce re-offending. PCE are playing a key role in this focus, integrating prisoners into both its manufacturing and assembly operations.
Workshop 5, an exciting and revolutionary initiative led by PCE with support from Serco, sees prisoners nearing release provided the opportunity to learn new skills and prepare for life after release by creating a new career pathway. PCE are training and upskilling participants, teaching them how to operate and excel in a manufacturing environment. PCE engage Release on Temporary Licence (ROTL) workers within its assembly teams.
For more information visit: www.pceltd.co.uk
Images: 01-02. HMP Fosse Way, Houseblock 8 is employing the PCE HybriDfMA Secure Prison system. Courtesy PCE Ltd
MODULAR HEALTHCARE
TWIN MILESTONES FOR LINCOLNSHIRE CDCS
An exciting milestone has been reached in the development of two new community centres being built simultaneously in Skegness and Lincoln using steel framed modules.
The external structures of the two community diagnostic centres (CDCs) in Skegness and Lincoln are now in place at the halfway point for the £38million build programme. A total of 71 offsite manufactured structural units have been craned into place – 42 in Lincoln and 29 at Skegness – to create the buildings.
The contract for Lincoln and Skegness is one of several won by MTX to build CDCs across the UK, employing modern methods of construction (MMC) techniques to deliver the projects faster, safer, greener and more cost effectively while maintaining the highest quality standards.
The new CDCs being delivered concurrently by MTX incorporate precisely engineered structural steel modules, which were factorymanufactured e while groundworks were under way on-site to create the foundations for the new buildings.
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Mechanical and electrical (M&E) services are manufactured as modules where appropriate to speed up the construction process and reduce costs.
Work is now progressing at a rapid pace to fit out and equip the state-ofthe-art facilities for their specialist roles offering a variety of diagnostic services, including X-ray, MRI, CT and nonobstetric ultrasound.
Professor Karen Dunderdale, Group Chief Executive of Lincolnshire Community and Hospitals NHS Group said: “The progress that has been made since planning permission was granted earlier this year is fantastic and we are currently on track to deliver these new facilities for Lincolnshire’s patients before the end of this year.
“We know that when anyone needs a diagnostic test, they want to access this quickly to support the rest of their ongoing care. Our CDC programme, through our first CDC on Gonerby Road in Grantham and temporary facilities in Lincoln and Mablethorpe, is already making a significant difference in improving access, and we’re confident that these new facilities will continue to reduce waits and make testing more convenient.”
Each CDC is designed to consider the health needs of the local community. In Skegness, plans for the Old Wainfleet Road site include a dedicated chemotherapy room to reduce the amount of travel necessary for cancer patients and a dental X-ray. These services, along with MRI and CT scanning, have not previously been available in the town. Lincoln CDC, which is on Lincoln Science and Innovation Park, will have dedicated training facilities to support the training of future radiographers, with ULHT becoming one of the first NHS Trusts in the country to link directly with a school of radiography at the University of Lincoln.
MTX Managing Director David Hartley added: “We are delighted that NHS Trusts are choosing to partner with MTX for delivery of these new resources based on our proven track record of rapid and cost-effective delivery. The creation of a network of CDCs is a key element in improving access to care and patient experience, and we are proud to be part of this vital initiative to reduce waiting lists.”
Partners from a range of organisations, including the NHS, local councils, local businesses and the construction teams involved in the builds, held a celebration at each site to see the progress being made. MTX continues to refine its innovative MMC solutions in line with the latest Design for Manufacture and Assembly (DfMA) principles. Quality is maintained, waste is reduced by up to 60% and delivery is faster, greener and more cost-effective. Time on-site is reduced by up to 50% with steel-framed building components manufactured under factory conditions while at the same time sub-structures are prepared on-site, shortening the overall programme.
You can watch a time-lapse video shows the speed and efficiency of offsite process being used to build the CDC at Skegness at: https://youtu.be/ reo1JZEf-ZU?si=vkjnI6aQ63R8UFS5
For more information visit: www.mtxcontracts.co.uk
Images: 01-02. Skegness CDC progress and team
At Jones Engineering Manufacturing Ltd., our mission is to drive the transformation of the construction industry through Modern Methods of Construction (MMC).
Our purpose-built manufacturing facility established in 2019, is a 15,000m² production site with a multi-discipline specialist team
bringing a change towards a more e cient process for our customers; allowing our Clients to maximise the potential of their project under one roof from Design through to O -Site Manufacture & Assembly.
We serve sectors including Data Centres, Biotech, Life Sciences, Food & Beverage, Energy, and Infrastructure.
TACKLING THE PRISON OVERCROWDING CRISIS
The UK’s prisons are full to bursting point, creating a critical issue for the new Government. Chris Turner, Managing Director of Integra Buildings, examines the vital role modular construction can play in addressing the prison overcrowding crisis.
Tackling overcrowding in UK prisons is without doubt a ‘Category A’ priority for Sir Kier Starmer and his new Labour Government. The riots which swept across towns and cities this summer and led to more than 1,000 people being arrested and 600 charged, served as a stark reminder of the importance of addressing prison overcrowding. Even before the riots, the scale of the issue had been laid bare.
Just days after the General Election in July, Sir Kier described prison overcrowding as “shocking” and said the situation was “worse than imagined.” With many prisons labelled as being “on the brink of collapse”, the initial response of the new Government was to announce plans to release thousands of prisoners early.
1The scale and urgency of the issue was further underlined when Ministers unveiled Operation Early Dawn, under which defendants waiting for a court appearance will be held in police custodial cells rather than prisons. It’s clearly a hugely difficult challenge for the Government to address, and one which requires effective solutions that can be implemented rapidly.
While the measures already announced will undoubtedly help to alleviate the issue in the short term, more permanent solutions will be needed. These could include creating additional prison capacity, either by extending existing prisons or building entirely new ones. If that does happen, modular construction should be at the forefront of decision-makers’ minds.
A tested solution, ready to be deployed at pace
Modular construction holds so many benefits over traditional building methods. New prison accommodation could be built at pace, without compromising on quality, while modular construction also provides flexibility and a range of sustainability benefits. At Integra, we believe modular can – and should – play an important part in unlocking the prison capacity conundrum. That’s why we’ve designed, created and tested a modular prison cell which can be deployed at pace. Built with a concrete floor and a non-combustible lightweight steel frame, the cell utilises an innovative composite construction, the exact make-up being commercially confidential.
The cell can be built to a variety of sizes, to suit specific population needs, and incorporates a shower and wash basin, alongside a bed and living space. After undergoing prototype testing at our site in East Yorkshire, the cell was taken to the BRE Science Park in Watford, one of the UK’s leading research and testing facilities. There, the cell was put through its paces in laboratory testing conditions to ensure it met all the Government regulations for use in the UK prison and justice sector.
We’re proud to say the unit exceeded requirements, meeting all the relevant criteria for use in Category C resettlement prisons – defined as housing prisoners who “cannot be trusted in open conditions, but have neither the resources nor the will to make a determined escape attempt.” In short, we have a tailor-made, tried and tested modular prison cell which is ready to be manufactured at scale. It puts us in a strong position to support the Government’s efforts to address prison overcrowding.
Modular makes sense
Why is modular construction the ideal solution for building prison accommodation rapidly? It comes down to a number of factors. Modular construction is significantly faster than the traditional bricks and mortar approach. Should the Government decide modular construction will be its method of choice to tackle prison overcrowding, cells could be manufactured quickly and at scale.
As well as being faster to produce, modular construction ensures exceptional quality control. Factory building removes many of the on-site delays and complications which can arise during traditional construction, making it a reliable and robust option. Modular construction also comes out on top when it comes to flexibility. Units can easily be extended or relocated in future, should the need arise, and can even be hired to provide a temporary, short-term security solution.
Another benefit of modular is its inherent sustainability. Offsite construction produces less waste than traditional methods, with manufacturing practices easier to control, and other factors including transport movements can also be minimised. Plus, the fact modular units can be re-used or relocated makes offsite construction kinder to the environment than traditional buildings.
Finally, modular construction typically does not suffer from the delays and disruption which can be caused by adverse weather. With manufacturing taking place in a controlled factory environment, less time is required onsite, and that means less time for our British weather to wreak havoc.
VOLUMETRIC MODULAR
A flexible answer to a pressing problem
Ahead of the General Election, the Ministry of Justice had announced plans to build six new prisons to create an additional 20,000 places. The new Government has re-affirmed it wants to build more prisons, but further details – including how those prisons will be built – have yet to be announced.
Going down the modular route would avoid committing to expensive new bricks-and-mortar jails. Modular-built prison cells or blocks offer much greater flexibility – they could be repurposed for other uses if no longer needed in future or relocated to meet demand in specific areas of the country. Longer-term, a broader reform to the penal system may well be required to manage prison occupation
levels, but the problem is pressing right now. Should the Government decide increasing prison capacity is, at least, the immediate solution to overcrowding, then modular should be at the heart of the strategy.
For more information visit: www.integrabuildings.co.uk
Images:
01. Integra Buildings Managing Director Chris Turner, left, and Head of Technical Richard Constable with the modular cell.
Courtesy Integra Buildings
02. The cell underwent rigorous testing at BRE Science Park in Watford.
Courtesy Integra Buildings
03. Integra Buildings provide steel-framed modular products from its base in Paull, East Yorkshire. Courtesy: R&R Studio
04. A modular apartment designed to help combat homelessness for More Housing. Courtesy More Housing 4 3 2
SHAPING A SUSTAINABLE FUTURE WITH MMC
The ecological clock is ticking, and designers must take urgent action to mitigate the impact of global warming. Richard Hipkiss, Development Director of the MPBA explains how volumetric technology can support net zero targets.
Recognising and finding ways to meet the requirements of changing regulations and policy demands is crucial in reshaping an architectural approach to sustainability. According to the World Green Building Council, construction and buildings in use are responsible for 39% of all carbon emissions in the world. This is broken down into two elements with 11% being linked to the manufacture of materials and construction processes – our embodied carbon emissions –and 28% associated with operational emissions – those caused by heating, cooling and lighting systems when a building is in use. Our challenge is therefore two-fold.
Cutting carbon in construction
A study by academics from the University of Cambridge and Edinburgh Napier University revealed construction using precision manufactured modular systems can produce 41-45% less carbon than traditional methods. Managed by architects HTA Design for Tide Construction and Vision Modular Systems, the research shows embodied carbon produced during the design, construction and decommissioning phases of a development, is dramatically lower when modular systems are used because buildings require less volume of carbon-intensive products such as concrete and steel.
Designing for manufacture and assembly (DfMA), rather than fabrication on-site, achieves the optimal use of materials. Modular buildings are less susceptible to poorly specified products as time can be taken upfront to validate the correct specification. Any surplus materials are recycled or reused for future projects. It is widely recognised that modular methods reduce the overall construction programmes, but it is not often acknowledged this approach can reduce up to 90% of the waste generated when compared with traditional construction processes.
Circular by design, modular architecture lends itself to a closed
loop of renewable materials and energy to achieve circular economy principles. The most compelling arguments for the carbon benefits of modular construction come from the reduction in time on-site and the optimisation of logistics. It is now well established that volumetric modular technology is a game changer for the construction industry – reducing build times by an impressive 50% according to data from members of the Royal Institution of Chartered Surveyors (RICS). Using cutting-edge digital design and manufacturing technology combined with the ability to carry out on-site groundworks at the same time as manufacturing modules, the efficiency benefits of this most advanced of offsite construction methods cannot be overlooked.
Reducing operational emissions
When designing a building to reduce carbon, small changes in the design and manufacturing processes can make a big difference to the operational carbon a building will use in its lifetime. The precision manufacturing involved in modular construction can support whatever energy efficient design is required by limiting heat loss caused by thermal bridging, along with far greater accuracy of construction. This allows for maximising the efficiency of the building envelope, reducing air permeability and minimising the amount of energy required to replace lost heat.
Factory manufactured modular buildings are highly accurate, well insulated and airtight, with air permeability of 1.5-3 m3 @50PA being the norm. A key advantage of modular construction is the benefits which come from working in a controlled environment. By producing buildings in a factory setting, the quality of elements such as insulation can be better assured. Predictability of in-use performance is a substantial benefit in not only achieving net zero goals but reducing primary energy requirements and in-use operational emissions during the lifetime of the building.
MPBA
Client satisfaction
With its powerful combination of controlled deliverables and customisable outputs, modular construction provides cost and time efficiencies together with repeatable quality and safety –meeting key sustainability drivers and stringent Building Regulation protocols. Ensuring the regulatory ‘golden thread’ of information, 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. Modern methods of construction (MMC) help ensure client satisfaction and product assurances through the certainty and quality embedded into the manufacturing process.
For more information visit: www.mpba.biz
Images: 01-03. Modular buildings can reduce both embodied and operational carbon levels dramatically. Courtesy Premier Modular 3
The MPBA plays a key role in the connecting of sectors in the modular and portable building industry. The association| collaborates with specialist technical advisors to enhance innovation in the design and manufacture of modular buildings. These can be designed and manufactured from timber or steel in any size and shape to meet individual client needs while ensuring full compliance with Building Regulations. Head over to OFFSITE EXPO Stand B01 where experts will be on hand to offer advice and support.
MPBA
HIGH END MODULAR LIVING
In a constantly developing and changing modular construction world, Purpose-Built Student Accommodation (PBSA) is a thriving sector. As part of this growth, Stelling Properties are forging ahead with many successful projects.
Stelling Properties is a fourth generation, privately owned property developer and steel-framed modular manufacturer. As well as constructing schemes for its own residential property development arm, it also works as a trusted partner to contractors, developers and asset managers.
“We are in a unique position with our modular offer,” says Director Anthony Broome. “Our offsite construction solutions are proven and are continually honed with our own multi-occupancy residential schemes. We have developed some really
challenging sites which would have been extremely difficult to construct using in-situ construction.
“This gives us a very unique perspective and a compelling proposition for other construction clients, particularly property developers, as we fully understand the development cycle – from land sourcing, design and planning to modular manufacture, offsite fitting out and the management of retained assets. We aspire to be one of the very best modular manufacturers in the UK residential sector. We are also privately owned which we believe gives us more
flexibility, agility and integrity and that really appeals to private sector developers.”
As well as Stelling’s property development and modular manufacturing operations, the business also owns Unilife, which manages and operates high-end student accommodation. This provides even more valuable insight that continues to inform its modular design, manufacturing and fitting out of new multi-occupancy residential schemes.
Demand for PBSA remains strong
The PBSA sector across the UK remains buoyant. In cities such as Southampton and Birmingham, there is still a significant under-supply of quality accommodation to meet demand, particularly for higher-end developments targeting international students. “We have plans to increase production capacity as demand for our modular solutions continues to rise over the next five years from both internal and external clients,” says Anthony Broome. “We are looking at high-end student living projects in cities around the country and our expansion into apartments for market sale and later living or retirement housing is another logical progression for us. On every project we are committed to achieving architectural design excellence and to delivering quality buildings for residents using advanced steel-framed offsite technology.”
Southampton projects
Stelling’s modular project in Southampton, 31 High Street is now nearing completion and follows its successful delivery of another student scheme on the same street last year – 112-114 High Street. That was an existing student block that was extended during occupation using its
VOLUMETRIC MODULAR
modular system. The new purposebuilt accommodation was then integrated into the original refurbished building.
It is now preparing to start manufacture of a third PBSA project in the city which is almost opposite 31 High Street. This is a commercial building which will be demolished and replaced with 100+ new high specification student bedrooms. “The parallel working that is one of the key features of offsite manufacturing allows construction and fitting out to progress in the factory while demolition works and foundations are underway on site”, adds Anthony.
Modular construction is far more sustainable than in-situ construction, offering enhanced thermal efficiency,
31 HIGH STREET
less material waste and fewer vehicle movements to site. Programme times are reduced for faster return on investment, build quality is improved and highly constrained city centre sites can be developed with ease, as well as less disruption to the locality.
Away from PBSA, Stelling are delivering multi-occupancy housing for short-term tenancies such as for homeless people and migrants –which is built to the same stringent standards – plus its residential focus on ‘negotiated’ projects remains.
Anthony concluded: “As well as continuing with our own developed projects, we are keen to grow our work with external clients and developers, which is a key part of our vision. The fact that our offsite solutions are tried and tested with our own developments gives our clients even greater peace of mind and confidence in our modular system, building solutions and capabilities.”
For more information visit: www.stellingproperties.com
Images: 01-02. Modules being craned in at 31 High Street, Southampton 03-04. 112-114 High Street, Southampton, will be new purpose-built accommodation integrated into an original refurbished building 2 3 4
Stelling’s offsite construction projects for external residential clients tend to be land-led and negotiated rather than tendered. This approach lends itself very well to developing longterm partnerships and collaborations.
A £12million regeneration scheme will restore and revive a historic site in the centre of Southampton, recently reached a major construction milestone. The installation phase for all 121 studio apartments, which were manufactured and fully fitted out offsite, has now been completed on-site with the cranage of the final modules.
31 High Street is a landmark project which is bringing a fire damaged building back to life after it remained derelict for more than a decade. The Portland stone façade of the former Bank of England building has been restored and other parts of the original building have been retained including the historic bank vaults in the basement.
The development represents a £12million investment by Stelling to regenerate this prominent site on Southampton High Street whilst helping to meet the critical undersupply of student accommodation in the city. The five-storey scheme will provide 121 high specification, self-contained studio apartments which will be operated by Unilife and are due for completion later this year.
Steel-framed, 8m long modules, each weighing up to 12 tonnes, contained a single apartment and arrived on site completely finished, with kitchenettes, shower rooms, fitted and loose furniture, flooring, doors, and glazing already in place. These were lifted into position over a six-week installation phase and using a 230-tonne crane.
Dan Smith, COO of Stelling Properties said: “31 High Street has been a hugely challenging and constrained site to develop. It demonstrates the enormous potential of offsite construction and our technical capabilities very well. The site is completely enclosed on three sides, which would have been extremely difficult for in-situ construction as there is no storage space for plant, materials or equipment. Speed of construction was absolutely critical to reduce disruption in the city centre. By manufacturing and fully fitting out the apartments offsite, we reduced time on-site by around 50%. The tremendous progress so far is a real credit to our design, production and site teams.”
The final phase of construction will include mechanical and electrical connections on-site, fitting out the extensive social and amenity spaces for residents in the original retained part of the building, roofing works, solar panel installations and landscaping of a large roof terrace.
TIME FOR TRANSFORMATION
Jaimie Johnston MBE, Bryden Wood’s Head of Global Systems is a familiar face across the offsite world and took some time to speak with us about the role of DfMA and transforming construction.
Bryden Wood’s trademark ‘design to value’ approach to projects and the use of reference design, has seen them streamline a variety of creative and functional tasks across the construction sector and also span pharma, data centres, infrastructure, healthcare, education and the aviation sectors. Does this demonstrate that designing offsite products and technologies, whether by standardising or automating assets and processes –with a DfMA mindset - can work in construction? And can this value driven design model differentiate between success from failure?
“Yes, we certainly think so,” says Jaimie. “We started out with a real interest in design for manufacture and assembly (DfMA) and offsite construction, and I think it's quite easy to get carried away and think that’s the goal. But you quickly realise that if you apply DfMA, you can be saving cost and carbon and increasing safety quality.
“Virtually every client is building as a byproduct of some bigger purpose. Pharmaceutical companies are trying to heal the world, they happen to
need buildings to do that, but it's not the end goal in itself. The ‘design to value’ phrase came from asking about adding value to clients to help them achieve that bigger outcome, and central to repeatable designs is the concept of design it once, optimise it and use it many times. All of these are aspects of asking what the best possible thing is we can do for clients, and what's the best way we can service that bigger business outcome or societal outcome that clients are seeking.”
Don’t be siloed
With the increasing use of digital design and visualisation tools in construction, why are we still seeing projects not getting off the drawing board or not reaching a successful completion? “My personal view is that it's because of the way the different stages of the project aren't linked,” says Jaimie. “The way that projects are traditionally procured is a very linear process. There’s a concept phase, a design phase, a delivery phase and handover.
“Those are quite siloed and often people don’t understand the design or the construction, delivery and operation aspects of their design decisions. People are using digital tools and they're using them for their particular stage, but it's not necessarily to join things up and quite often those are handed over to the contractor and suddenly the price goes through the roof. Or the contractor ‘value engineers’ it and dilutes the architectural concept, to make it easier to build, but they've lost something that was vital about the concept that was helping serve the client.
“This lack of continuity through the process means that you quite often find something that was unexpected and stops the project, so the tools are fantastic, but if they're not joined up
throughout the process, then you're not solving the problem.”
What words of wisdom would you give project managers and consultants who are working with offsite design and manufacturing? “We were set up specifically to properly integrate the design process, trying to take a very holistic view and constantly looking at eventual project outcomes. Not necessarily the asset itself, but what it does for the client? I think we should have the mentality of: what are we doing to help the end purpose and the end goal of the clients? You should have a more altruistic view of it.”
DfMA challenge
Since the publication of your three books on the subject, what are your current views on DfMA, how has it evolved and how have your expectations changed? Jaimie says: “The first book we put out on platforms, which is this idea of repeatable components that can get used across sectors, which was published in 2017. That idea hasn't changed. There’s more and more evidence around why it's a good idea and the potential impacts. The thing that I find interesting now is the amount of evidence there is, but there's a gap between what we know is a good idea, and our ability to deliver it, because of the way contracts and procurement frameworks have been created.
“I don't think the challenges now are technical, it's all to do with the ecosystem and with business models. During the session I'm hosting at OFFSITE EXPO, I’ll be talking about a practical guide to some of the steps that we can take. I think most people will understand the benefit, but don't know where to start, so I’m going to explain some of the practical steps that we can take to really start transforming construction.”
OFFSITE OPINION
Events such as OFFSITE EXPO can work as catalyst for driving change across the construction industry. Do you think they can create a more collaborative culture amongst the many stakeholders in the industry as well? “I think more than can –
P-DFMA – HOW TO DEFINE IT
they must,” says Jaimie. “Everyone knows the huge challenges facing construction. What we do in the next 20-30 years will define humanity forever, so anyone who's got anything to contribute to making construction better should be publishing it, should
be talking about it and they should be sharing best practise. Events like this are critical as a forum for us to move the industry forward. Events like this where we collaborate, share our story, share best practise and learn from each other are so important. That's how we're going to truly start to transform construction.”
For more information visit: www.brydenwood.com
Images:
01. Jaimie Johnston MBE, Head of Global Systems, Bryden Wood
02. Bryden Wood have produced three landmark publications on Platform Design
Jaimie Johnston will be taking part in the Platform Design and DfMA Masterclass Session on 17 September at OFFSITE EXPO.
As outlined in ‘Platforms in Practice: a lean approach to industrialised construction’, a Platform approach to Design for Manufacture and Assembly (P-DfMA) identifies features such as floor heights and structural spans that are shared across different types of buildings (e.g. schools, apartments and healthcare facilities) to reveal the kit of standardised parts that can be used to deliver assets across multiple sectors.
These parts are readily available from existing suppliers and can be assembled easily and intuitively, in countless ways, to sustainably create a huge range of spaces. Using these repeatable, cross-sector components creates the economies of scale that have allowed the manufacturing sector to continually drive down time and cost while increasing safety, productivity and quality.
This approach also allows the application of automation - both in the manufacture of individual components, and in the assembly processes that create whole assets on-site. It is this automation that has the potential to transform the productivity of the sector, as we have seen across so many other industries.
The concept of platforms, common in manufacturing sectors, and how they might be applied in construction, was first set out in Bryden Wood’s 2017 publication ‘Delivery Platforms for Government Assets: Creating a Marketplace for Manufactured Spaces’. This arose from a programme of works that was being developed for the Ministry of Justice (MOJ), which demonstrated the power of thinking across sector boundaries.
Delivery Platforms identified three potential superstructure platforms that would deliver the majority of public sector assets (broadly Platform I – small span, Platform II – mid-span and Platform III – large span). Of these, Platform II is the one with the most potential for mainstream and widespread application.
Platform II is a product platform: it is a system for the main structure of a wide range of buildings (for instance, schools, hospitals, prisons, commercial and residential) with a common mid-span range (6m - 9m). The system can deliver this variety of buildings with a limited set of components (e.g. standardised steel columns, standardised connection brackets and optimised in-situ concrete floor) with clear interfaces that allow other systems to complement it to deliver the full building.
The components of this system are conceived such that they optimise the construction process of the buildings while doing so with a minimum of standardised components. This makes it possible to create pipelines for large quantities of these standardised components (scale of quantities of components for the relevant scale of the different types of buildings) and significantly increases the benefits of using this product platform industry wide.
A key aspect of Platform II is that it is designed as a ‘carrier frame’ to enable a range of complementary products to be developed and to maximise productivity in their installation. This has already been demonstrated through the manufacture of mechanical, electrical and plumbing (MEP) cassettes and façades.
Both ‘Platforms in Practice: a lean approach to industrialised construction’ and ‘Delivery Platforms for Government Assets: Creating a Marketplace for Manufactured Spaces’ are freely available to download from Bryden Wood at: www.brydenwood.com
AI AWARENESS LESSONS REQUIRED
With artificial intelligence (AI) seemingly becoming a part of everyday life, recent research from BSI suggests the built environment sector is one of the least prepared to make the most of this part of the digital revolution.
In July BSI published its ‘International AI Maturity Model’ and accompanying ‘Trust in AI’ report, which used global analysis to assess seven sectors against how ready to adopt AI tools they are. The built environment sector came sixth out of seven sectors just ahead of healthcare. It also found that UK businesses were far less likely to have scaled up investment in AI or AI-enabled tools over the last year versus businesses in the USA, China, Australia, India, France and the Netherlands. Findings from BSI’s ‘Trust in AI’ research relevant to the built environment sector found:
• Nearly a quarter (24%) of built environment businesses are not currently investing in AI
• But 86% of built environment business leaders said they were likely to invest in AI or AI enabled tools in the next 5 years
• 77% of built environment businesses leaders said that their business encouraged the use of AI, compared with 54% of healthcare business leaders
• Just 37% of built environment business leaders say that their business has an AI strategy in place
• Global poll of business leaders across nine countries reveals that UK and Japanese businesses are least likely to encourage the use of AI and least confident in their ability to harness it.
China and India leading BSI’s model assesses and weights a suite of measures including organisational confidence and readiness for AI adoption amongst businesses globally, to come up with a single score. It identifies India as the most AI mature market, scoring 4.58 to China’s 4.25. Based on insights from 932 business leaders across nine countries and seven sectors, metrics include attitude and actions including investment, training, internal and external communications, and safety. The analysis identifies the UK and Japan to be less mature relative to others, potentially influenced by factors including policy direction or media narratives focused on risk rather than opportunity. On all measures,
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China and India led the way, with the US in third place, followed by Australia.
Some 65% of UK business leaders said that they thought that their business encouraged the use of AI, versus 96% of Chinese business leaders and 94% of Indian business leaders. Similarly, 72% of UK business leaders said that they were confident in their business’s ability to harness the benefits of AI, the second-lowest result of all nationalities surveyed (putting it ahead of Japan, at 50%). 96% of Chinese business leaders and 94% of Indian business leaders were confident in their business’s ability to harness the benefits of AI.
Interestingly, there does seem to be a link between confidence and investment in AI and the firm belief in the need for up-to-date regulation and guidance. The research identified gaps between perceptions of what successful AI adoption entails and concrete steps being taken. More than three quarters of international business leaders (76%) think organisations will be at a competitive disadvantage if they do not invest in AI. Yet 30% felt not enough was being invested by their businesses in AI tools.
“BSI’s International AI Maturity Model paints a positive but nuanced picture of a world excited about AI’s potential and its promise as a force for good,” said Susan Taylor Martin, BSI’s CEO. “Some countries and some sectors are pulling ahead while for others there is a journey still to go on to build trust and confidence. Investment in standards, training and assurance is key as AI becomes integral to the future of life and work.
“While the Model shows diverging paths thus far on AI, its mass adoption and integration into work and life is a marathon, not a sprint. Success is not about being first, but about building trust. BSI is committed to playing a role in shaping the guardrails for the safe and ethical use of AI, which will help businesses globally respond to embrace AI to build a positive future for all.”
Improving productivity
BSI also explored where leaders see scope for AI, with 55% saying the key opportunity is around improving productivity and efficiency, closely followed by improved customer service (46%). A quarter see it as a tool to reduce reliance on contractors or consultancies, while nearly two fifths (38%) expect AI to support the management, measurement and reporting of sustainability goals, and 40% expect to use it to support cybersecurity. Under a third globally (31%) anticipate AI changing or replacing specific job functions. BSI’s research draws together four key takeaways exploring how businesses can act to shape trust in AI across their ecosystems and wider society, so AI can be realised as a force for good. These include:
• Think long-term: look at AI as part of your wider business strategy –once the foundations are in place, businesses can optimise and evolve their AI strategy as technology advances
• Businesses and policymakers should collaborate across borders: the goal must be to innovate with AI, but to do so safely. Alongside
regulatory routes, cross-border collaboration can offer necessary protections
• Move from intention to action: instil trust in AI by clarifying priorities and accelerating progress towards them
• Lead and inspire: set the standard for an AI future in which the technology is a force for good.
The offsite sector can be viewed as an industrial and technologically driven one. The end result may be a’ building’ but the steps to get to that end goal are in the hands of digital tools, software and automation. Everyday construction processes can be streamlined and rendered defect-free via robotics with AI saving workforces significant amounts of time, allowing them to focus on higherimpact outcomes, reduce labourintensive tasks and boost productivity.
Automation can optimise various aspects of construction projects including planning, design and supply chain resources. AI-driven software can analyse vast amounts of data to identify patterns and predict outcomes. This helps everyone involved in a scheme to make informed decisions. As highlighted by the BSI research those working in the built environment need to educate and equip their teams on the developing world of data analytics, machine learning, and software use. By equipping workers with these skills, AI solutions can be used effectively, leading to a new generation of higher quality and ‘smarter’ built environment.
For more information and to explore the huge amount of data on BSI’s interactive dashboard visit: https://bit.ly/478SSsn
Images: 01-03. AI and digital tools will only play larger parts of the way that buildings are designed, built and maintained 2 3
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