Offsite Magazine - Issue 6 (June 2017) by Radar Communications

OFFSITE DEDICATED TO OFFSITE DESIGN, MANUFACTURE & DELIVERY | JULY 2017 ISSUE 06 | £4.95

TAKING OFFSITE CONCRETE TO NEW HEIGHTS

P20

APEX HOUSE Process efficiency at Europe’s tallest modular building

P36

SMART CONSTRUCTION Standards and technical guidance from NHBC

P58

COURTING CURVES Steel frame walls at the home of tennis

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PUBLISHER: Offsite Magazine is produced and published by Radar Communications: ©Radar Communications Ltd. Radar Communications Ltd, 5 Darwin Court, Oxon Business Park, Shrewsbury, Shropshire. SY3 5AL T: 01743 290001 www.radar-communications.co.uk For offsite enquiries please contact: E: info@offsitemagazine.co.uk DISCLAIMER: The content of Offsite Magazine does not necessarily reflect the views of the editor or publishers and are the views of its contributors and advertisers. The digital edition may include hyperlinks to third-party content, advertising, or websites, provided for the sake of convenience and interest. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any advertising or products available from external sources. No part of this publication may be reproduced or stored in a retrieval system without the written consent of the publishers. All rights reserved.

OFFSITE SKILLS ARE YOUR BUSINESS

Welcome to the July issue of Offsite Magazine and one that follows on from an extraordinary UK election result that seems to have confused many and pleased very few.

What the impact will be on the UK construction sector and housing market in particular is hard to predict. Housing Minster Gavin Barwell – a champion of offsite manufacture – lost his MP status (but is now Conservative Chief of Staff) so hopefully the momentum created over the last 18 months will not stall at the highest level. One thing for certain is that concentrated efforts to invest and develop the right skillsets and construction expertise for generations to come has never been higher. This is reflected in several features in this issue. The creation of the Ministry of Building Innovation (MOBI), where Teesside University in partnership with architect and TV presenter George Clarke, has launched new courses in Advanced Home Construction all with an offsite flavour could be the shape of things to come – see more in our news pages. The latest construction industry analysis to fathom the impact of offsite construction comes from the Construction Industry Training Board (CITB). Its report ‘Faster, Smarter, More Efficient: Building Skills for Offsite Construction’ looks to provide a:

“robust evidence base of the likely nature of industry demand for skills, training and qualifications in offsite construction and onsite assembly over the next five years.” The solutions are easy to spot but tricky to solve.

Key features come from the NHBC and BOPAS. Neil Smith, NHBC’s Head of Research and Innovation reveals they are witnessing an upsurge in interest in offsite construction, with increasing numbers of systems and components being put forward for assessment against the NHBC Standards. The same story applies to BOPAS. Jeff Maxted, Director of Technical Consultancy at BLP Insurance, has much to say about the recent boom in BOPAS registrations and enquiries. Exciting project development stories comes from Lee Newman, Chief Executive of offsite building specialist Elliott, who explains more about ilke Homes – the exciting hybrid timber and steel construction joint venture with Keepmoat Homes – and with strawberries and cream on the horizon we have a special case study update on what EOS Facades are doing at Wimbledon Court Number 1. Special thanks to all our contributors, advertisers and supporters including Creagh Concrete for our cover story. Enjoy.

Gary Ramsay

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

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

The Crescent, Plymouth – Image courtesy of the Pickstock Group

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CONTENTS

COVER STORIES P06 | TAKING OFFSITE CONCRETE TO NEW HEIGHTS

32 | The Road to Smart Construction How can the Buildoffsite Property Assurance Scheme (BOPAS) assure quality for the offsite sector and help it address the UK housing and skills crisis? Jeff Maxted, Director of Technical Consultancy at BLP Insurance, tells us more.

P20 | MODULAR STACKS UP

The current pace of change in offsite technology and the emergence of new construction options is unprecedented. Creagh Concrete represents a combination of innovation with a solid track record in offsite manufacturing and outline how they are pushing back the boundaries with offsite concrete systems.

Apex Tower in Wembley is set to be Europe’s tallest modular development rising to 28 storeys and taking just 12 months to complete. This symbolic development proves that offsite construction can deliver massive benefits at speed and at scale.

P36 | ENSURING NEW HOMES STAND THE TEST OF TIME

P58 | COURTING CURVES

Under its headline banner of ‘raising standards, protecting homeowners’, the NHBC plays a pivotal role in the UK housing sector. Neil Smith, NHBC Head of Research and Innovation, outlines its role in supplying guidance and information on prefabrication and offsite manufacture.

Wimbledon – home of the All England Lawn Tennis & Croquet Club – commissioned a new open/close roofing solution for Court Number 1 with EOS Facades designing two walls to envelope the entire circumference of Court Number 1.

NEWS

FEATURES

08 | Offsite News News and developments from across the UK & International offsite industries and wider construction arena including: Teesside University and architect and TV presenter George Clarke’s Ministry of Building Innovation, launch of new demountable bathroom pods and DfMA schools complete in Bradford.

22 | Offsite Awards 2017 The entries for the 2017 Offsite Awards were collated, judged and scored. Take a look at the shortlisted and winning projects and people from across 14 categories that showed off the best that offsite manufacture and delivery can do for the UK.

39 | ilke Homes – a glimpse of the future? Lee Newman, Chief Executive of offsite building specialist Elliott, explains why the next generation of offsite-assembled homes is surprisingly traditional in design. 44 | Precast View for Alder Hey Alder Hey Children’s Hospital is the only hospital in a park in Europe and sets a new benchmark for the delivery of modern healthcare for children. The purpose-built £250 million development is one of the most ambitious medical construction projects ever undertaken in the UK. 50 | Perfect Panels for UPP In partnership with the University of London, University Partnerships Programme (UPP) appointed a project team to redesign the existing student accommodation at Garden Halls. This included an innovative, eye-catching new precast facade designed by tp bennett in partnership with Maccreanor Lavington. 54 | Standardisation in Modular Construction: Possible or Desireable? A key strength of offsite construction rests in its repeatability and standardised set of components but as Mark Lawson of the Steel Construction Institute (SCI) explains, ‘standardisation’ can have various meanings in the construction sector. 68 | Super CLT Structure for Fife The new single storey Kelty Community Centre, located within the main street of a former West Fife mining village also has a linked connection to the adjoining primary school and showcases the exceptional use of cross laminated timber (CLT). 74 | Offsite: Faster, Smarter, More Efficient The latest upswing of interest in offsite manufacture could change the construction industry fundamentally and provide a solution to the UK housing shortage, but as a new Construction Industry Training Board (CITB) report shows, only if the sector develops the right skills. 78 | Ecobuild: The New Approach Big changes are planned for the 2018 event including the introduction of the Offsite Construction District.

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COVER STORY CREAGH CONCRETE

TAKING OFFSITE CONCRETE TO NEW HEIGHTS The current pace of change in offsite technology and the emergence of new construction options is unprecedented. Creagh Concrete is in that mix, representing a combination of innovation with a solid track record in offsite manufacturing. Here they outline how they are pushing back the boundaries with offsite concrete systems. “Investors not only benefit from revenue gained by the early occupation of units but, also, from the mobility of their capital resource. Quite simply, shorter build times mean developers can complete more projects with the same pot of finance. The market for custodial accommodation has also been open to offsite for some time now and we are engaging there too.”

1 Several factors are driving interest in offsite, with contracts being signed at a rate not previously experienced by the industry. The acceleration in this market is partly explained by the well-reported pressures in housing, driving continued growth in the pool of investment available for apartment schemes in the private rental sector. Add to that the nationwide demand for newbuild student accommodation and you begin to understand why offsite construction in the multi-storey residential market has established such a solid base.

Creagh are championing the use of precast concrete through the application of their Rapidres fastrack build system, which is currently winning residential apartment projects of up to 22 storeys. According to Managing Director, Seamus McKeague, the funding arrangements for the private rental sector favour offsite for faster turnaround on projects. “We are seeing strong interest in our rapid build concrete systems because developers now understand the true value of slashing programme times,” says Seamus.

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

Rapidres is a good example of the application of structural cross wall design, which is ideally suited to multi-storey projects where the layout is replicated consistently across each floor. While most projects will have variation of layout in mixed use spaces on the ground floor, this is routinely dealt with by the use of a structural podium which forms the base for the offsite structure.

COVER STORY CREAGH CONCRETE Another area where concrete excels is in fire performance, as its noncombustible nature reduces potential spread of fire, providing an important safety benefit for residents and protection for the building itself. This risk reduction can be an attractive selling feature to both the developer and their clients.

4 While precast structures have been around for a long time, it is the development of more choice in high quality exterior finishes which is contributing to their current popularity. The factory applied, exterior finishes of high performance, insulated concrete, sandwich wall panels can match that of virtually any other build type. These now include various brick finishes plus an array of smooth, etched, patterned and even printed concrete finishes with additional options for profiles and textures.

Like many of the alternative offsite construction options, Rapidres also dramatically reduces the need for wet trades on site. The high quality finish on the interior walls are pre-painted with a mist coat while pre-fitted electrical conduits, back boxes and the use of bathroom pods reduce the workload for trades on site. Externally, the factory finish and preinstalled windows negate the need for scaffolding, further boosting efficiency and making an important contribution to enhanced health and safety on site.

These choices unlock the market for systems like Rapidres because developers are now able to break free from the idea that offsite manufacture is a limiting factor in the design, an important fact as individuality is increasingly an important factor when creating desirable living spaces.

The inherent structural characteristics of concrete enable Creagh to prefit items such as balcony supports. This facilitates the fast installation of balconies which can be pre-assembled on the ground prior to being craned into position and secured. The advantages of concrete precast offsite solutions, however, go far beyond just the speed of construction, creating differentiation from most other systems.

The panelised factory manufacture facilitates the rapid rate of assembly on site however the reduced programme times are also driven by additional features in this style of construction. As each floor is assembled, it creates a safe, contained workspace for followon trades which can commence work whilst the subsequent floors are still being installed. The envelope will also be weathertight early in the build, as doors and windows can be pre-fitted offsite.

Precast concrete brings big acoustic benefits, as its characteristics provide excellent barriers to sound, providing acoustic separation between living spaces and from external noise. These inherent features can result in cost savings as they reduce the need for supplementary noise control measures. Similarly, concreteâ&#x20AC;&#x2122;s thermal mass can make a significant difference to how a building performs, particularly with regards to reducing the risk of overheating and the potential to reduce energy costs associated with heating and cooling.

Concrete is a tried and tested material with outstanding robustness and durability. The self-finished surfaces offer longevity of service advantages over other built-up systems and are more resilient against wear and tear or deliberate damage than the materials used in alternative lightweight offsite builds. Taken together, the combination of efficiency in the build phase with the whole of life benefits, makes Rapidres a highly attractive proposition for developers seeking offsite speed without compromise in finished build quality and performance.

RAPIDRES IN ACTION Creagh Concreteâ&#x20AC;&#x2122;s latest Rapidres projects in construction include several large residential developments going on site this summer. Arena Central in Birmingham comprises two buildings, with 17 and 22 storeys respectively, providing a total of 323 apartments. This is the second application of Rapidres on a project for Dandara Group/Galliford Try following a highly successful build on the Forbes Place apartment development in Aberdeen. The scale of the Arena Central development demonstrates the efficiency offsite brings through the factory manufacturing process, as it handles some 14,000m2 of facade walls and over 18,000m2 of floors. Two further apartment blocks, at Glasgow Harbour will also go on site this summer and incorporates underground car parking over two levels, with 12 and 16 storeys of apartments above. You can view more on Rapidres here: http://bit.ly/2rRH2AN

For more information visit: www.creaghconcrete.co.uk or email: structures@creaghconcrete.co.uk Images: 01. Precast panel being craned into position 02&03. Forbes Place, Stoneywood 04. Arena Central, Birmingham

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

OFFSITE NEWS George Clarke and Teesside University Launch Offsite Courses

Contractors Appointed to Fusion21’s Mega Million Modular Framework Fusion21 has announced the contractors successfully appointed to its national Education Modular Buildings Framework, worth up to £225 million over a four year period.

Teesside University is launching a suite of groundbreaking new courses in partnership with architect and TV presenter George Clarke, through his Ministry of Building Innovation (MOBI) initiative. George Clarke and MOBI’s mission is to kickstart a fundamental change to the building industry, attracting new generations into the profession. Teesside University has developed a suite of courses in Advanced Home Construction starting with a Higher National Certificate and Diploma, an undergraduate degree programme, BSc (Hons) Advanced Home Construction (top up) and a postgraduate degree course – MSc Advanced Home Futures. The courses take a new look at the building industry and offer a broad-based practical approach which aims to attract learners from different disciplines, not just traditional architecture and enable students to explore a variety of specialisms, allowing them to challenge the status quo. Students will engage with industry and explore the concept of home, different aspects of living spaces, digital solutions to create innovative approaches to address the issues of the built environment. “MOBI is about training, retraining, making, building and creating innovative twenty-first century homes that genuinely improve the way people live,” says George Clarke. “We need to teach the new generation of students how to think differently to challenge the norm and look for new ways of doing things.

“The slow and antiquated method of building new homes is painful and, fundamentally, we still build homes the way we did hundreds of years ago. Whilst technology corporations, telecommunication companies, the automotive and aerospace industry are advancing at incredible rates, the house building industry is stagnant and it’s genuinely time for systematic change. There is a need for exciting innovation, opportunities to push the boundaries of what we build and how we build that will attract bright new minds in to the industry.” The courses will offer the added advantage of working closely with industry and with some of Teesside University’s specialist facilities including Middlesbrough Institute of Modern Art which is looking at social issues such as housing, MOBI-Lise, a dedicated workshop on campus to allow students to make and test items and RIBA, the Royal Institute of British Architects which will give access to their online library resources. Professor Tim Thompson, course leader, explained: “These courses are designed to produce students ready to make a disruptive change to a traditional industry. With MOBI aspirations at the forefront of what we deliver, we’ll encourage creativity, independent thinking, leadership skills and artistry to address a social need.” Full details of the courses, which start in September 2017 and how to apply are available at: www.tees.ac.uk/advancedhome

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

A total of nine specialist firms from across the UK have secured a place on the framework – which offers four lots including: Lot 1: Hire of Modular Buildings – Temporary Accommodation, Lot 2: Modular Construction with a value of up to £750K, Lot 3: Modular Construction with a value between £750K and £3 million and Lot 4: Modular Construction worth £3 million and over. In addition to the appointment of multiple specialist suppliers, Lots 3 and 4 sought a single supply partner with Wernick Modular Buildings Ltd being successfully appointed. This approach ensures that Fusion21 members accessing this framework – including local education authorities, academies, colleges and universities – will benefit from significant efficiency savings and social value, plus other advantages including competitive tension, early supplier engagement and transparency of costs. Nick Verburg, Procurement and Supply Chain Manager at Fusion21, said: “This framework offers a flexible procurement solution to all education providers and local authorities who require permanent or temporary safe learning spaces to cope with growing student numbers – and seek quality modular buildings which are compliant with all building regulations and present lower carbon emissions than traditional builds. Accessing the single supply option will also generate enhanced value for money for Fusion21 members – providing opportunities for collaborative working and early supplier engagement which will drive down costs and time efficiencies at the design stage of a project.” The framework went live on 1 June, 2017. Source: www.fusion21.co.uk

OFFSITE NEWS New Demountable Bathroom Pods Available

New Roofing Guide to Boost Housebuilders’ Use of Offsite Components

New roofing guidance endorsed by the NHBC has been published by the Trussed Rafter Association (TRA) and is designed to reduce the risks, costs and waste from poor spandrel panel construction by housebuilders. In a recent NHBC survey of 8,000 new homes sites, about 17% were already using spandrel panels. Trussed roof manufacturers report increasing interest in these offsite components, especially from large and volume housebuilders building low-rise housing and apartments. The new guide for masonry-built homes provides evidence-based technical best practice on the design, structural requirements, fire and acoustic performance, weather protection and safe installation of spandrel panels.

Offsite Solutions, one of the UK’s leading bathroom pod manufacturers has developed an innovative demountable pod solution for refurbishment and newbuild projects where there is insufficient access for fully assembled pods. Originally developed for military refurbishment projects, the demountable pod option is now available in the complete range of GRP bathroom designs. Demountable pods radically reduce work onsite and offer the superior and consistent quality of factory-built bathrooms. Eight pods can be reassembled onsite in just one day with a three-person team. This compares to site-built bathrooms on a typical scheme, which can take 6-12 weeks to complete using multiple trades and requiring a high level of site management and supervision. In refurbishment and conversion projects, the only access may be through the window openings of an existing building – or internally via the main entrance and stairwells – and this may not be sufficient for a full-sized pod. The panel sizes of a demountable pod are specially designed to ensure full access is achievable. Demountables can be an efficient solution to maximise offsite construction on newbuild schemes where pods may not have been considered at design inception. Some areas may not have access for siting an assembled pod because of beam locations, columns or a complex architectural design.

The use of a demountable solution for these areas and pre-assembled pods for the rest of the building, means that bathroom build quality is maintained across the whole project, with a single point of contact and significant programme savings. Ian Packer, Senior Project Manager of construction company ISG, commented: “Building bathrooms onsite for multi-occupancy buildings does not make sense in my view and I would always recommend a pod solution. The demountable pods are a clever way of overcoming any access issues to maximise offsite construction. Speed on site with a sectional form is still much faster because the number of operations, trades and drying periods are reduced to just one company and a single assembly operation. Why have up to seven different trades and 10-15 operations onsite when you can have just one?” James Stephens, Managing Director of Offsite Solutions, added: “Bathroom pods have traditionally been limited to newbuild. The development of our demountable solution expands the application of offsite to refurbishment and conversion projects. We can deliver, position and reassemble factory-built bathrooms in a sectional configuration in a fraction of the time of site-based construction and with enhanced quality. This helps to reduce the reliance on subcontracted trades, at a time when the construction industry is facing such severe skills shortages.” Source: www.offsitesolutions.com/demountables

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

Jonathan Fellingham, Chairman of the TRA, said: “As the use of pre-manufactured components and offsite construction grows in popularity, housebuilders are increasingly turning to spandrel panels. They provide an ideal solution to the skills shortages in housebuilding and roofing, and they help to improve safety onsite, as they require less time working at height. Spandrel panels can be installed quickly, and faster installation times also mean lower costs. They also leave little or no site waste. “But TRA members and NHBC inspectors have shared concerns about the quality of construction in some areas, so it’s vital that housebuilders understand best practice in design and installation to achieve the best results. We have collaborated with the STA and NHBC to ensure the challenges housebuilders face are covered so the standard of installation is as high as possible.” Paul Cribbens, NHBC Standards Manager, added: “As the housebuilding industry moves evermore towards innovative methods of construction, it is encouraging to see the supply chain embracing the challenges and ensuring that products perform as expected. This document represent a first significant step towards standardising this innovative method of construction.” The guide has been developed by the TRA in association with the NHBC and the Structural Timber Association (STA). It is available now as a free download from the TRA website. Source: www.tra.org.uk

OFFSITE NEWS Scottish Offsite Consortium Win Collaboration Prize

Together with a number of public sector partners it aims to realise the full potential of Scottish offsite manufacture by improving the working environment in the construction industry, reducing waste from that sector, and significantly improving the performance of buildings in terms of construction, comfort and longterm running costs. Calum Murray, Chairman of the Hub, said: “Support in translating ideas into practical action will be hugely useful for us and we plan to utilise this support from Scottish Enterprise. For instance, in approaching UK wide institutions with the right message as a group, the assistance will be essential. We are exploring other possible uses for the funding and support, including a ‘learning journey’ being proposed for Sweden next year and representation at a conference on offsite construction in Salford next year.”

A new consortium of firms involved in offsite construction is celebrating after winning a share of the £60,000 Collaboration Prize, delivered by Co-operative Development Scotland on behalf of Scottish Enterprise and Highlands and Islands Enterprise. Launched for entries in September 2016, the Collaboration Prize attracted a record number of responses from across Scotland.

The Scottish Offsite Hub, which formed following the UK government’s release of its 2025 Construction Strategy identifying offsite construction as a vehicle for delivering improvement targets for the construction sector, scooped one of the six £10,000 awards. Comprising nine companies, the Hub’s goal is to promote improved market awareness, address emerging skills challenges and to foster a collective approach to ongoing research and development in the use of timber construction technology.

The member businesses in the Scottish Offsite Hub are: CCG Off-Site Manufacturing, Alexanders’ Timber Design, Carbon Dynamic CLDB Ltd, MAKAR Ltd, Oregon Timber Frame Ltd, Robertson Group, Scotframe Timber Engineering Ltd and the Stewart Milne Group. Source: www.scottish-enterprise.com

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JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

OFFSITE NEWS MEDITE SMARTPLY Announces Major Investment in New Factory

New Offsite Construction Centre Targets ‘Triple Threat’

MEDITE SMARTPLY, producers of innovative timber panel products, has signed a commitment as part of a consortium planning the construction of the world’s first Tricoya® wood chip acetylation plant. To be built in Hull, the plant will produce the raw material for the manufacture of MEDITE® TRICOYA® EXTREME, the market leading high performance wood panel. The consortium is between MEDITE SMARTPLY, chemical technology group Accsys, venture capitalists BP Ventures and Acetyl industry leader BP Chemicals. The plant, due to come on stream in 2019, will produce Tricoya Wood Elements using Accsys’ proprietary technology for the acetylation of wood chips and particles. These acetylated elements are used to manufacture the high performance MEDITE TRICOYA EXTREME medium density fibre panels. The panels exhibit outstanding durability and dimensional stability which allow them to be used in exterior and wet area applications once limited to products such as concrete, plastics or metals. With the added benefits of lightweight, sustainable raw materials and a guarantee of up to 50 years above ground and 25 years in ground, these panels provide architects, specifiers and designers with an entirely new construction material, allowing great design flexibility and endless opportunities for creativity. Neil Foot, MEDITE SMARTPLY CEO said: “The commitment to develop this facility is a huge step forward, providing the opportunity to significantly increase our manufacturing volume and unlock interesting new markets where wood-based products would not previously have been applicable. It’s a very exciting development for the company and the construction industry as a whole.” Two years in the planning, the €68 million venture will see the construction of a new factory adjacent to BP’s existing acetyls facility and the place where much of the original research and development into wood acetylation was carried out. For MEDITE SMARTPLY this is seen as a game-changing development, enabling the rapid development of the market for MEDITE TRICOYA EXTREME into a new era for the use of “high technology wood” in new applications.

A new project between construction and academia, spearheaded by Stewart Milne Timber Systems, aims to address the ‘triple threat’ to the UK’s new homes ambitions – shortages of materials, skills and quality new housing. Stewart Milne Timber Systems, the UK’s leading timber systems designer and manufacturer, has joined forces with Napier and Heriot-Watt Universities, and industry partners CCG Construction Group, to develop an offsite construction centre of excellence at its Oxfordshire manufacturing facility. This offsite construction ‘hub’ will develop industry-focused and interactive training with the ambition of creating a highly skilled offsite construction workforce. The project is part of a wider national initiative, run by the UK Commission for Employment & Skills, which is looking at innovative ways to tackle the skills shortage in offsite construction. Industry professionals from housebuilding, affordable housing providers, contractors, architects and technical and construction teams, are encouraged to visit the centre and complete the Stewart Milne Timber Systems Competency Scheme, achieving different levels of certification depending on which aspect of training they complete.

Source: www.meditetricoya.com

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

Stewart Dalgarno, Director of Product Development at Stewart Milne Group said: “The UK’s shortage of housing is well-documented, but solving a challenging problem is made even harder by a persistent and chronic lack of skilled labour. Currently there are not enough people to build the UK’s shortfall of homes. Realigning the industry around offsite construction with timber systems means the UK will be less constrained and less dependent on current trade skills. “The project is the beginning of an answer to this triple threat to the country’s housing ambitions, and having experts from industry and academia working together means we are in a strong position to deliver something meaningful for the good of the whole industry and the UK housing market.” The project includes a timber systems offsite manufacturing technical training centre at Stewart Milne Timber Systems’ facility in Witney, Oxfordshire. The centre includes a product gallery, conference centre, and learning centre which gives visitors the chance to visualise the construction process end to end, view training videos, interact with the latest technology and take part in simulations. It also includes a training rig to allow hands-on experience of the real-life process of construction. Source: http://timbersystems.stewartmilne.com/

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OFFSITE NEWS Offsite Top of the Green Sky Agenda

FastHouse Announces ‘New’ Solution to Housing Crisis

An innovative new housebuilding solution has the potential to transform the building process and reduce the shortages in the housing sector in Northern Ireland (NI) by reducing completion times by an average of 70%, according to modular construction company FastHouse.

Offsite was the topic of discussion at Levitt Bernstein and Innovaré’s Green Sky Thinking event in May. ‘Offsite: design meets manufacture’ comprised an exhibition, conceptual pod and panel discussion exploring the emergence, challenges and opportunities posed by offsite, as well as the role it could play in solving London’s housing crisis. Nicky Gavron of the London Assembly, spoke of the “crucial watershed” for London’s housing, suggesting that the construction industry needs to “think and build differently” if we are to ease the shortage of new homes, and that offsite poses a “massive opportunity” to do so in London. A number of options were discussed, from pooling sites for scale efficiencies to joining manufacturing centres together. Andy Gatrell of Swan Housing, explaining the company’s plans to open its own factory later this year, demonstrated how offsite has huge potential for developing high quality homes quickly. At full capacity, their Basildon factory will produce 300 cross laminated timber (CLT) homes per year. Offsite has suffered from negative perceptions in the past – something which is now slowly shifting, according to Levitt Bernstein’s Zohra Chiheb. She discussed how the architectural ambitions for offsite have changed since the era of the prefab, saying: “Designers have a better understanding of the long term impacts of buildings, which is evident in the quality of what is being delivered now.”

She went on to stress that: “early collaboration between architects and manufacturers is essential in ensuring quality for new homes”. This also plays a vital role in allowing for flexibility later in a building’s life, meaning it can accommodate household or tenure changes, for example. Discussion amongst guests, a mixture of design professionals, consultants, project managers, private developers, housing associations and local authorities, revealed a general enthusiasm for offsite, with the main challenge felt to be in its implementation. Many suggested GLA support, or new policies encouraging the use of offsite construction, would be welcomed. As well as the panel discussion, a conceptual pod, designed by Levitt Bernstein and manufactured by Innovaré using structural insulated panels (SIPs), was on display to demonstrate the flexibility of the system through its bespoke, faceted form. Visitors were invited to experience the space and appreciate that offsite has gone beyond the production of repetitive, modular buildings so often associated with it.

The company has completed the first two semidetached homes in Windrush Park, Antrim utilising offsite construction technology which reduced the construction period from 16 to three weeks. FastHouse’s modular timber system will enable quality homes to be built more quickly and is vital if NI is to tackle the shortage of housing and skills in the local market. Stephen Bell, Managing Director of FastHouse said: “Traditional construction methods have changed very little over the decades due to the conservative nature of the industry. Even the use of traditional timber frame construction in NI only accounts for 15% of newbuild homes compared to 33% in England and 75% in Scotland. “We are delighted to complete our first project for Lagan Homes which has resulted in a fully completed house within three weeks of the FastHouse installation team first moving onsite. We strongly believe that offsite manufacturing isn’t the future of the housebuilding industry, it’s the today.” FastHouse’s signature closed panel timber frames leave the factory insulated with service conduits and electrical boxes installed, windows pre-fitted and dry lined, ensuring minimal waste and maximum efficiency.

The pod itself is a visual representation of the offsite process, with the two elements signifying the two key parties involved: designer and manufacturer. These combine to form a porch and chimney, the former representing the initial stages of the manufacturing process with the raw materials revealed, whilst the latter is finished using a render system to illustrate the construction process. There are plans for the pod and accompanying exhibition to travel to another location later this year.

Conor Mulligan, Managing Director of Lagan Homes, part of the Lagan Group added: “We are all aware of the housing crisis in NI and we can see first-hand the contribution FastHouse has been able to make to this development at Windrush Park. By building quality homes in an extra efficient way, FastHouse will significantly speed up housing provision in Northern Ireland as well as advancing the sustainability agenda. For the builder, in this climate of limited bank lending, the ability to increase turnover of ‘work in progress capital’ from three times a year to perhaps ten times a year will have substantial appeal.”

Source: www.levittbernstein.co.uk

Source: www.fast-house.eu

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

OFFSITE NEWS First Three Yorkshire PSBP Schools Complete Yorkshire Learning Partnership has announced that the first three schools in the Yorkshire Batch of the Priority Schools Building Programme (PSBP) have been completed to programme and have opened on the planned dates. The three schools to open are Beckfoot Upper Heaton and Samuel Lister Academy, both in the Bradford Metropolitan area, together with Harrogate High School in North Yorkshire. The Yorkshire Batch of schools is comprised of seven schools in West and North Yorkshire, and has been procured by the Education Funding Agency. The project will deliver circa 63,283m2 of new teaching accommodation which will benefit in excess of 7,000 students. The learning environments have been designed around double and triple height community spaces, such as halls and dining areas, to provide an abundance of natural light throughout the buildings. Each school also has a new standalone Sports Hall. The new accommodation will replace outdated buildings in need of repair, with facilities suitable and fit for the 21st Century.

In addition to providing new school buildings, the project also provides hard Facilities Management (FM) services to the schools for a concession period of 25 years. Funding for the £120m project is provided via a Private Finance (PF2) arrangement, from a consortium of lenders secured through an Aggregator vehicle, Amber Infrastructures. Yorkshire Learning Partnership is a Special Purpose Vehicle (SPV) selected by the Education Funding Agency to construct the schools and provide the FM services. Partners in the SPV are Equitix, Laing O’Rourke PLC, and IUK Investments (HM Treasury’s vehicle for investing equity in PF2 projects).

Laing O’Rourke Construction has been contracted by Yorkshire Learning Partnership to carry out the construction of the buildings and provide the FM service. To construct the schools Laing O’Rourke has utilised its Sigma system, developed by the company as a standardised method of school design and construction utilising their DfMA (Design for Manufacture and Assembly) product range. This offsite manufacturing approach, combined with engineering expertise of the project teams, has provided high quality construction standards, reduced design lead times and enabled successful delivery to tight programmes. Source: www.laingorourke.com

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OFFSITE NEWS £3m Investment for Integra Buildings

Modular specialist Integra Buildings has announced a £3 million investment to capitalise upon rapid growth in the sector. The company – one of the UK’s leading designers and manufacturers of offsite constructed modular buildings – has purchased six acres of industrial land for £1.6 million and plans a further £1.4 million investment. The location at Paull, east of Hull in East Yorkshire, is adjacent to a 2.5-acre site already owned and operated by Integra Buildings. The acquisition will enable the company to launch a programme of capital investment to increase manufacturing capacity and take advantage of major opportunities in a sector experiencing significant expansion. Integra Buildings Managing Director Gary Parker said: “This major investment will allow the physical expansion we need to enable our business to grow and move to the next level. This is the perfect time for us to develop more of the innovative manufacturing processes for which we are noted and strengthen our position as a leading player in the UK modular buildings market.” The strategic development plan includes the creation of two bespoke production facilities, amounting to 72,000sq ft of manufacturing space within existing buildings on the site. The investment will bring together in one place all the company’s production of modular buildings for permanent installation for clients across a wide range of sectors and highly durable and anti-vandal modular buildings used predominantly for construction sites. The new, state-of-the-art facilities will be fully operational by early 2018.

Integra Buildings Commercial Director Chris Turner added: “The old image of modular buildings as prefabs is a thing of the past. Modular building is the way forward in the construction industry. A wide range of sectors are recognising the benefits of modular, offsite construction and we are seeing that in the exceptionally strong demand for our products. We’re passionate about this form of construction and with this investment we will be practising what we preach by creating our own new modular office block, showcasing the superb quality and innovation we offer to our clients.” Integra Buildings’ steel-framed products are structurally guaranteed for up to 60 years and are built and pre-assembled in factory conditions and the modular units are installed onsite typically in between one and five days. Integra’s modular buildings can also incorporate traditional materials such as brick and stone and mirror the aesthetics of ‘conventional’ structures. Integra Buildings has doubled turnover to almost £19 million over the past five years. Among the company’s flagship schemes are a new modular nursery and community space for learning disability charity Mencap in Leeds and the bespoke changing, strength and conditioning and physiotherapy facilities for the British Olympic rowing team at Eton Dornay, Buckinghamshire, which were used in preparation for the 2016 Games in Rio de Janeiro. Source: www.integrabuildings.co.uk

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

Richmond Gets First L&G Home London housing provider Richmond Housing Partnership (RHP) will be the first recipient of modular homes from Legal & General (L&G). The LaunchPod was designed for RHP by former Rogers Stirk Harbour & Partners architects William Wimshurst and Leonardo Pelleriti’s Wimshurst Pelleriti practice. William Wimshurst said: “RHP were adamant throughout the R&D process that they did not want to use space-saving gimmicks such as fold-down beds that are maintenance heavy and typically associated with small spaces. Their aim throughout was to provide high quality accommodation that did not compromise on quality or the feeling of space.” RHP chief executive David Done added: “I was blown away when I first saw the prototype – it is spacious, modern and high quality… and will contribute to our target of investing £250m in new affordable homes.” L&G is targeting the delivery of 3,500 modular homes a year from its factory and recently appointed former Rolls Royce business Development Director Rosie Toogood to lead its modular housing operations. L&G are in discussions with Richmond Council over a 30-home development featuring homes intended for the intermediate market – for those who do not qualify for social housing but are priced out of the private market. Source: bit.ly/2sZJSTj

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EXPLORE OFFSITE EDUCATION

NEXT GENERATION EDUCATION INVESTMENT Now in the second phase £2.4 billion of the original budget has been allocated to PSBP2 to rebuild and refurbish individual blocks at 277 schools. The scale of the task is vast and requires a serious asset management programme to deliver the required short and long term benefits. Only through using innovative construction solutions can the PSBP be delivered. Keith Waller, Senior Advisor at the Infrastructure & Projects Authority understands the challenge: “Infrastructure is not only about new projects – 95% of the assets we are going to need in 20 years’ time are here already. We need to keep that focus on the performance of the current asset base as well as how we deliver new assets more effectively.”

1 Explore Offsite is a series of events which take the form of combined conferences and exhibitions. The latest event focuses on the future of offsite construction in the education sector and will bring together technology leaders to discuss the many opportunities offsite technology can offer the construction industry. In February 2017, the National Audit Office – the body that scrutinises public spending for Parliament – found that a large number of school buildings in England required substantial repairs. It is estimated that it will cost £6.7 billion to return all school buildings across the country to a ‘satisfactory or better’ condition, and a further £7.1 billion to bring parts of school buildings up to a ‘good’ condition.

These estimates are rooted in a Department of Education property data survey, completed in 2014 – four years after the launch of the £4.4 billion Priority School Building Programme (PSBP). This Programme is set to run until 2021 with the aim of rebuilding or refurbishing a total of 537 primary, secondary and special education needs schools across England.

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

Offsite construction has been making the news recently after Head of Construction at the Cabinet Office, David Hancock, put forward the building method as a way to solve some of the issues afflicting the construction industry. The second phase of the PSBP presents a major opportunity for offsite construction to play a crucial role to help meet the challenging targets. One of the most frequently cited benefits of offsite construction is the speed of delivery that it offers, with the time required to construct and commission an offsite building being typically reduced by 50 - 60% in cases where large elements can be prefabricated. The PSBP relies heavily on standardisation to reduce costs. So, will the use of offsite manufactured classrooms and other education facilities increase? Richard Crosby, Director of Education at management consultant Blacc and an independent consultant to the Education and Skills Funding Agency (ESFA) believes it will. “I see modular construction playing an even greater role in PSBP2,” he says.

EXPLORE OFFSITE EDUCATION “This phase represents one of the biggest opportunities for modular construction in the market. The ESFA understands the need to design and procure for offsite construction and they are working on a component solution of standard blocks that can be assembled to create bespoke schools without compromising on quality of design or specification. The ESFA’s modular schools will look and feel like traditional build schools in a fraction of the time onsite.” Richard Crosby also maintains that the volumetric modular systems that have made such recent and significant inroads in low-cost housing construction will also be more apparent with PSBP2. “The fact that schools are much bigger and more complex buildings than houses has been a challenge but this type of construction makes sense as it minimises disruption to live learning environments and offers reduced construction periods. The results of how the ESFA has responded to this challenge will be seen in the forthcoming procurements under a range of frameworks and rollout programmes.”

Learn more about offsite construction and the opportunities in the education sector from the key speakers – both Richard Crosby and Keith Waller will be presenting at the Explore Offsite Education conference, taking place on 11 July 2017 at Westminster, London. Joining them on the speaker platform will be Rachel Stephenson, Programme Director Education & Skills Funding Agency, Bryan Evans, PSBP2 Project Director and a host of experts from the offsite sector. This integrated conference and exhibition event creates a platform for construction clients, architects, engineers and contractors to come together and discuss the latest offsite solutions in the education sector. For the full speaker line up or to book your place visit: www.exploreoffsite.co.uk/2017events/explore-offsite-education

3 Images: 01. Neasden Primary School Courtesy of Education and Skills Funding Agency 02. Lynch Hill Enterprise Academy Courtesy of McAvoy Group 03. Redmoor Academy ‘Schoolhaus’ Courtesy of Net Zero Buildings

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APEX HOUSE 2017 Offsite Awards Winner for Best Use of Steel

MODULAR STACKS UP Apex House in Wembley is set to be Europe’s tallest modular development rising to 28 storeys and taking just 12 months to complete. This symbolic development proves that offsite construction can deliver massive benefits at speed and at scale. The 560-bedroom student accommodation block will comprise 679 separate modules, including 242 modules in two eight-storey wings on either side of the tower, produced by manufacturer Vision Modular Systems at its factory in Bedford. The volumetric modules were delivered fully kitted out with a kitchen and bathroom, services, light fittings, switches, socket outlets, internal finishes and even the bases for the beds are installed. The rapid-fire development involved modules being transported down the M1 to London, then lifted by tower crane from the trailer and into position in just 10 minutes. Up to 11 modules were installed per day, which has enabled the project team to slash the construction programme to just 12 months. The project overturns the conventional view that modular is more expensive than traditional construction, says Rory Bergin, Partner at HTA Design. “The whole question of whether modular is a bit more expensive than traditional in terms of up-front cost doesn’t matter. What matters is saving 12 months of time, which a group of professionals – including clients, builders and manufacturers – could use to build another building, making the capital cost almost totally irrelevant.”

It is the fourth modular block to be built on a single parcel of land inside the Wembley Regeneration Area, by the same developer – Donban Construction. The four projects were all delivered with variations of the same modular system led by Donban’s manufacturing arm Vision Modular Systems, HTA Design, main contractor Tide Construction and M&E supplier Red Electrics. This integrated set up has helped increase the pace of delivery increasing the number of modules installed per day from five or six to 10 or 11. The building frame is a hybrid, comprising a reinforced concrete core, concrete foundations with a series of concrete columns at ground level that support a transfer slab on level two. The transfer slab provides vertical support for all the modules above, which are stacked one on top of the other. The modules are produced in eight different configurations and vary in weight from around 12 tonnes to 17 tonnes. A typical module comprises a bedroom, study area and en-suite bathroom with half of the modules including a section of corridor.

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Larger modules – installed at the corner of the tower – include common areas with a shared living/dining space. Every module is open at one end to allow services to be connected, including the soil vent pipe and electrics and to fit a door onto the corridor. The concrete core provides lateral support for the modules, with two steel bracing structures at the end of the two wings. Concrete floors in the modules act as a ‘diaphragm’ to channel lateral loads into the core. All units are welded together onsite to form the rigid honeycomb structure with the most complicated weld junctions where four modules come together on an external face. Supervising engineers photograph each weld detail to ensure quality control.

APEX HOUSE

MODULAR & STRUCTURAL INNOVATION Two key structural innovations were required to build the highest modular tower in Europe.

Apex House has a strong architectural presence with terracotta striped cladding panels of varying tones, elegant white GRC cladding, a fullheight strip of glazing on the corners and retail units on the ground floor set back from the chunky concrete columns. “We’re not interested in making schemes that look like they are modular,” says Rory Bergin. “We are interested in good townscaping, good placemaking and good urban design. Sometimes we have to push the manufacturer to do things that are a bit less efficient to improve the architecture, but they recognise that we want to deliver high-quality buildings that don’t look like boxes.”

The modular approach is suited to the tight nature of the site, where there was no room for materials storage, apart from a small courtyard to the rear and just one side road for deliveries. Using a modular approach resulted in a small workforce of only 22 onsite staff, eradicating the need for large areas for welfare facilities and site offices, normally associated with traditional build. It also improved health and safety by removing the need for scaffolding and allowing all external work to be carried out from mast climbers. The tallest modular tower in the world is a 32-storey residential tower, in Pacific Park, central Brooklyn, but Vision believes its system is capable of going even higher. “We are looking at other schemes that will take the height up into the mid-30s,” says Kieran White, Managing Director at Vision Modular Systems. “Fundamentally you are working with a steel structure so we could go higher.”

A special coupling arrangement, between the steel modules and the reinforced concrete core, had to be designed to accommodate differential movement, caused by the gradual settlement of the concrete structure over time. “We had to develop steel plates, cast into the core, form a horizontal tie with the modules and allow for some vertical movement,” says Kieran White, Managing Director at Vision Modular Systems. The modules each incorporate thick steel corner posts, designed to transfer vertical loads down into the foundations. The arrangement differs from Vision’s modules for low-rise properties, which include vertical studs at 600mm spacing designed to handle uniformly-distributed loads. The walls of modules are mostly infill structure, including boards for fire protection and internal finishes. The walls on the facade incorporate windows and insulation, ready for application of the GRC cladding onsite. “The units are entirely sealed off from the elements so that, once craned into position, internal works can proceed in parallel with external works. You don’t have to wait for the cladding contractor to give you a dry building before you can progress,” adds White.

Whether modular schemes like Apex House can trigger a paradigm shift in UK construction will depend on wider strategic political and economic goals. But the ongoing housing crisis, coupled with the possible impact of Brexit on numbers of migrant workers, are likely to make fast-build systems, which require fewer onsite operatives a very attractive proposition.

For more information visit: www.visionmodular.com www.hta.co.uk Images: 01-03. Europe’s largest modular tower comprises 679 separate modules craned into a tight urban site. Courtesy Vision Modular Systems

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

OFFSITE AWARDS 2017 The Offsite Construction Awards once again celebrated the best in precision building design and delivery recently by showcasing innovation, best practice and recognising overall expertise in offsite construction. The profile of offsite manufacture has never been higher with the bar now being constantly raised on quality and scope of delivery. The Awards reward outstanding examples of offsite manufacturing, prefabrication and factory-based methods, products, systems and disciplines that deliver a better built environment. This is all seen through landmark projects, influential people and the innovative use of materials and manufacturing expertise. The 2017 Offsite Construction Awards generated a record number of entries with over 200 high-quality submissions, making it a tough challenge for the judges to pick the winners – especially the Winner of Winners. The competition was extremely tough in many categories, reflecting the seismic shift in the development of the offsite industry and the significant growth in the uptake of offsite technology across a wide range of sectors.

For those that missed out here is a quick look at this year’s shortlisted entries. Winners of the Offsite Construction Awards were revealed at the Awards ceremony on 13 June in London. In the next issue of Offsite Magazine we will be featuring the winning projects in more detail – check the winners flash to see who won! You can also see the winners and highly commended collecting their Awards at www.offsiteawards.co.uk Many thanks to the sponsors, finalists and attendees and special thanks to all those that took the time to enter this year. See you in 2018, when the Offsite Awards will be moving alongside Ecobuild in March. Additional Sponsors:

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Project Manager of the Year

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Gerard Donnelly of the McAvoy Group, is seen as the very personification of the organisation’s trademark ‘Think Smart. Build Smart’ philosophy. A graduate of Construction Engineering and Management from the University of Ulster at Jordanstown, Gerard has a sharp eye for detail and approaches every project with the same meticulous planning and innovative mindset. His many personal innovations have led to a significantly improved delivery of service to McAvoy clients. His mode of management extracts the best from his teams, and his service to clients not only raises the bar on project delivery but also helps propel his company’s reputation to ever greater heights. Gerard was integral to the success of the brand new £20 million Lynch Hill Academy in Slough – understood to be one of the UK’s largest ever post-Primary modular schools and delivered 17 weeks early.

Offsite Professional of the Year

Sponsored by:

WINNER

02 01 Gary Mayatt - Enegroup Limited 02 Bradley Ashcroft- Actavo Building Solutions 03 HTA Design LLP 05 Mark Lewis - Trimo 06 Fusion Building Systems

04 Richard Crosby - Education & Skills Funding Agency

07 John Handscomb - Kier Construction

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Best Use of Concrete

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05 06

03 01 Thorp Precast

02 Kier Construction

03 SIG Offsite and H+H

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05 Maccreanor Lavington & TP Bennett

Best Use of Timber

06 Kier Construction

Sponsored by:

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01 Wiehag GmbH 02 PLP Architecture 03 Waugh Thistleton Architects 04 The Fairhursts Design Group 05 rg+p Ltd 06 Hewitt Studios 07 Spheron Architects 08 KLH UK 09 B & K Structures 10 Cartwright Pickard

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Best Use of MEP Prefabrication

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01 Polypipe Terrain 02 Alternative Heat 03 Nomenca 04 SES Engineering Services

Best Use of Steel

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01 Vision Modular Systems & MJH Structural Engineers 02 Trimo 03 EOS Facades 04 Icarus LSF 05 Kier Construction 06 Thurston Group 07 Cloud Offsite Construction 08 Kingspan Steel Building Solutions 09 EOS Facades 10 Fusion Building Systems

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Best Hybrid Construction Project

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01 Innovare Systems 02 Kier Construction 10 B & K Structures

03 The McAvoy Group 04 WB Timber Innovations 05 Kier Construction 06 Hewitt Studios 07 Elliott 08 Ilke Home 09 SIG Offsite and H+H

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Best Use of Volumetric Technology 01

06 WINNER

01 WestonWilliamson+Partners 02 Premier Modular 03 Enegroup 04 CargoTek 05 Premier Modular 06 Stride Treglown 07 Vision Modular Systems 08 Unity Partnership 09 Cloud Offsite Construction 10 Ilke Homes

Housing Project of the Year

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01 B & K Structures 02 Vision Modular Systems 03 Ilke Homes 04 Places for People X Urban Splash 05 SIG Offsite 06 Waugh Thistleton Architects 07 Premier Modular 08 ZEDfactory Europe 09 WestonWilliamson+Partners 10 Simon Conder Associates

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Healthcare Project of the Year

Sponsored by: WINNER

01 WSP Parsons Brinckerhoff 02 Kingspan Timber Solutions 03 Kier Construction 04 Portakabin 05 Kier Construction 06 Icarus LSF

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Education Project of the Year

WINNER

01 B & K Structures 02 Net Zero Buildings 03 Atkins 04 Elliott 05 Hewitt Studios 06 KLH UK 07 Unity Partnership 08 The McAvoy Group 09 Innovare Systems 10 Portakabin 11 Cartwright Pickard 12 Fairhursts Design Group 13 Maccreanor Lavington & TP Bennett

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Commercial/Retail Project of the Year

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01 07

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01 PLP 02 B & K Structures 03 Kier Construction 04 Trimo 05 LF Fasthouse 06 Fife Council Property Services 07 B & K Structures 08 Stride Treglown 09 Cartwright Pickard 10 Prater

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Infrastructure Project of the Year

WINNER

01 Wiehag GmbH 02 Premier Modular 03 SES Engineering Services 04 Atkins

Product Innovation Award

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02 WINNER

03 01 Offsite Solutions 02 Smartroof 03 coBuilder 04 Moduloft 05 Knauf Insulation 06 SIG Offsite and H+H

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BOPAS QUALITY ASSURANCE

THE ROAD TO SMART CONSTRUCTION

How can the Buildoffsite Property Assurance Scheme (BOPAS) assure quality for the offsite sector and help it address the UK housing and skills crisis? Jeff Maxted, Director of Technical Consultancy at BLP Insurance, tells us more. As Mark Farmer in his ‘Modernise or Die’ report makes clear, the UK housing sector is facing a crisis requiring a radical rethink of construction and procurement techniques. We must deliver an increase in housing supply at a time when the average age of the construction workforce is increasing – a potential time bomb that will play out over the next 10 years with net loss of 25% of workforce and which is likely to be exacerbated as the Brexit effect takes hold. We are finding it increasingly difficult to attract new talent into the industry and to replenish the level of leavers. This is resulting in a massive skills shortage across the industry. According to a report from the Union of Construction, Allied Trade and Technicians (UCATT) – ‘Constructions skills shortage is a result of 30 years of failure’ – the UK is facing its biggest skills shortage for a generation, with estimates showing that the construction industry needs 35,000 new entrants just to stand still. With a huge shortage of skilled workers in the UK, building firms have been forced to double the wages for tradespeople from abroad, increasing the cost of traditionally built homes.

There is a simple solution if the industry embraces offsite or non-traditional forms of construction and brings new players into the housing market. I shall refer to it here as ‘Smart Construction’. We must modernise the industry in a way which will: • Increase attraction to new entrants and offset attrition and shrinkage • Improve productivity so we can increase output with constrained labour.

Smart Construction essentially refers to any non-traditional form of construction methodology. Prefabrication in a factory setting is by no means a new concept and the benefits are clear: speed of construction, reliability of materials and manufacture, improved performance and potential reduction in construction costs if units can be delivered at scale and to repeatable design.

Conventional housebuilders continue to respond to what home buyers want and are unlikely to move fully to Smart forms of construction, although a number are trialling various offsite solutions. While they may engage with the concept on the periphery, the key growth area for offsite methods will be the burgeoning private Build to Rent sector (B2R). Most B2R and Housing Association developments coming to market can be replicated at scale and this model is suited to the offsite industry. Furthermore, funding in this sector will come predominantly from institutional investors looking to invest in secure large-scale developments, where the economic benefits will be matched by the consistency and sustainability that offsite manufacturing provides. For example Essential Living is building a 294 unit B2R development in Deptford using the Elements Europe volumetric modular system. Smart Construction will also become main stream in other sectors such as hotels and low cost home ownership through Registered Social Landlords.

Not only is this situation reducing output and increasing cost, quality is also suffering with an increase in construction defects and buildings not performing as designed. The industry, however, needs to look beyond traditional forms of construction. The requirement to fill the supply and demand gap must be met with housing that is both sustainable and of the highest quality. The traditional housebuilding community is neither able nor willing to change its business process and increase output to solve the problem.

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BOPAS QUALITY ASSURANCE

2 One of the main advantages of Smart Construction is in terms of quality. An article in the January 2016 issue of Planning and Building Control Today confirms that buildings in the UK currently fall short by up to 30% in terms of how they were originally designed to perform. Properties built in a factory will have a higher level of quality control compared with a construction site, improving the performance of the building over time. This improved performance from offsite techniques should translate into reduced energy and maintenance costs. We are already seeing major London centric developers such as Essential Living and Pocket Living utilising modular manufacturers such as Elements Europe and Vision Modular for large scale projects in London. Both manufacturers have gained Buildoffsite Property Assurance Scheme (BOPAS) accreditation giving the developers confidence to adopt this method of construction. The most attractive features of modular housing are the speed of construction and the potential for reduced cost of development. Another advantage is the particular suitability of this type of housing for â&#x20AC;&#x2DC;infillâ&#x20AC;&#x2122; sites where traditional construction site set up is difficult. Furthermore, this type of construction might attract investors which are not traditionally involved in the housing sector. Modular construction might be particularly suitable for market renting as the speed of construction means rental revenue is delivered quickly and investments can pay for themselves within a relatively short period. To date, the real level of innovation

and modernisation in the industry has been limited, being constrained by a reticence to invest in a cyclical, short term thinking sector with low levels of capitalisation. Mainstreaming offsite manufacturing for the UK housing sector will require coordinated action from Central Government and from the construction industry. It will need both policy from Government and persuasion from clients, together with decisive action from both the private and public sectors to enable manufacturing to mobilise. While the benefits of Smart Construction are clear, they do not come without challenges. Concerns about systematic failure, fire spread and water ingress, have been raised around the use of offsite techniques, both during and after construction. These concerns are being addressed by BOPAS which provides long-term assurance to mortgage lenders, valuers, funders, landlords and homeowners that properties built using non-traditional forms of construction will be durable for at least 60 years, without the need for disproportionate maintenance. BOPAS was launched in March 2013 and developed by Buildoffsite, Lloyds Register and BLP Insurance with Royal Institute of Chartered Surveyors (RICS), the Council of Mortgage Lenders and the Building Societies Association. The BOPAS process gives an independent assessment of quality and reassurance from inception through to construction for investors, developers and owners.

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Although take up of BOPAS in the early years was quite slow given the reassurance that BOPAS provides, Smart systems and other innovative construction methods can provide a sustainable, cost-effective solution to the increasing shortage of housing supply and there is currently a surge in interest from manufacturers seeking accreditation. We are now seeing a significant increase in registrations and enquiries, reflecting the increase in growth of offsite in the housing sector. BOPAS accreditation provides type approval in respect of a BLP Insurance Structural Warranty. Government support for offsite manufacturing is critical in keeping the momentum going and in its Residential policy, RICS urges ministers to support non-traditional construction and endorses BOPAS as an independent assessment process to ensure that such systems are durable for at least 60 years. Directly commissioned sites should represent the housing stock of the future. To give both lenders and consumers confidence in lending against these properties the Government should ensure a diverse mix of construction types should be built here such as offsite construction (e.g. both panelised and modular). In addition, we would like to see a commitment from the Government to explore the challenges across the sectors and to assess whether the provision of a Government guarantee would give the support and confidence needed to lenders, consumers and developers to kick start Smart Construction and move it into the mainstream. For more information visit: www.bopas.org www.blpinsurance.com Images: 01. The Essential Living/Elements Europe scheme in Greenwich, London 02. Interest in BOPAS registrations and enquiries has grown recently 03. Urban Splash hoUSe using the SIG modular system, Manchester

A site for sore eyes

Looking at the advantages of BBA Certification As you well know, major construction work on building sites involves a huge amount of product and materials checking, not least to make sure everything meets the exacting requirements of building regulations. This can be stressful at the best of times and a helping hand is always welcome. That’s why more and more people are coming to the BBA for off-site certification of their products. For many years now, our work in the offsite construction sector has brought peace of mind to hundreds of architects and manufacturers alike. BBA Agrément Certificates are widely read and respected by industry decision-makers who want to select innovative products that have been thoroughly assessed by the BBA. Our assessors have decades of experience in evaluating Offsite Construction, and we are currently assessing many new systems, adding to the many already approved including insulated concrete formwork, SIPs and framed systems. Of course, our main focus is on the requirements of Building Regulations — not just in England and Wales, but also in Scotland and Northern Ireland. But we go much further than that. We want to ensure that a system is not only waterproof, warm and structurally sound; it has to be durable, too. No-one wants to buy a system with a short life expectancy, so we seek to ensure that it will last for an appropriate period of time.

Neither are our assessments simply desk exercises. As well as testing, we go out to the factory to check system documentation and control, making sure that the specification we approve is capable of being produced consistently. We also go out on site to see units being offloaded and installed. That’s because we know that what may seem simple when explained in a dry office or factory can turn out to be very different on a building site. Once we have gathered data from testing, factory inspections and site surveillance, we consider how we can use it to establish that the requirements of Building Regulations and other statutory or non-statutory documents have been met. BBA Agrément Certificates are regarded as quite simply the best assurances you can get for your off-site products. With BBA’s 50 years of unrivalled expertise in building and construction certification, it’s easy to see why. clientservices@bba.star.co.uk www.bbacerts.co.uk 01923 665300

NHBC RAISING HOUSING STANDARDS

ENSURING NEW HOMES STAND THE TEST OF TIME Under its headline banner of ‘raising standards, protecting homeowners’, the NHBC plays a pivotal role in the UK housing sector. Neil Smith, NHBC Head of Research and Innovation, outlines its role in supplying guidance and information on prefabrication and offsite manufacture. Our insistence on ensuring that a high standard of durability is achieved reflects the length of time that NHBC has been in existence. Our interest extends well beyond the first ten years of the NHBC Buildmark warranty.

1 It is increasingly clear that boosting housing output at a time of declining availability of skills requires ever more innovation by the housebuilding industry and the greater use of modern methods of construction (MMC). As the Farmer Review and the Housing White Paper stress, without a change to the status quo, the prospects of making real progress in tackling the UK’s housing need are severely limited. At NHBC we are witnessing an upsurge in interest in offsite construction, with increasing numbers of systems and components being put forward to us for assessment against the NHBC Standards. Such reviews are essential, to be assured that homes and their component parts are designed, manufactured and constructed to consistently meet performance standards.

It is an established expectation amongst homeowners, landlords, investors and mortgage companies that new homes will last a very long time. Reflecting this expectation, NHBC explicitly requires a life of 60 years for the structure. This means that materials and components need to be selected and assembled carefully so that a 60 year lifespan can be achieved in reality, with the construction of the finished home having the durability and resilience to withstand the vagaries of the UK climate. In practice, homes designed for 60 years can be expected to last well beyond that time. NHBC was established in 1936 in response to the ‘Jerry building’ that was happening as towns and cities were being rebuilt following the First World War. A rush to construct large numbers of new homes quickly was causing major problems, with significant consequences for homeowners and mortgage lenders.

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NHBC Standards Our technical manual, the NHBC Standards, provides guidance for designers and housebuilders. Covering all parts of the home, they are written as ‘performance standards’ giving the flexibility in the use of various forms of construction and facilitating new approaches and innovation. Fundamentally NHBC requires the following five Technical Requirements to be satisfied: • Statutory requirements (compliance with Building Regulations and other statutory requirements) • Design requirement (design taking account of the location and use of the home) •

Materials requirement (materials to comply with accepted standards/certification)

• Workmanship requirement (satisfactory levels of workmanship) •

Structural design requirement (structural design by competent engineers in compliance with established codes).

NHBC and smart construction Working with industry to ensure long-lasting quality homes. n From component materials and design to onsite installation and connection n System appraisal and acceptance n Ensuring the whole building is constructed to meet NHBC Standards n Backed by NHBC Buildmark warranty and insurance

Talk to us... Call us now on 0344 633 1000 Email techservices@nhbc.co.uk or visit www.nhbc.co.uk/mmchub NHBC is authorised by the Prudential Regulation Authority and regulated by the Financial Conduct Authority and the |Prudential Regulation Authority. JULY 2017 WWW.OFFSITEMAGAZINE.CO.UK NHBC is registered in England & Wales under company number 00320784. NHBCâ&#x20AC;&#x2122;s registered address is NHBC House, Davy Avenue, Knowlhill, Milton Keynes, Bucks MK5 8FP.

L267 05/17

NHBC RAISING HOUSING STANDARDS The NHBC Standards are able to help normalise modern methods that are proving successful and gaining market share, by setting out clear, detailed technical guidance and benchmarks. This helps designers, constructors and our own Building Inspectors, who may not previously have encountered a particular method of construction. NHBC at the Heart of MMC NHBC is currently working with many designers, housebuilders and manufacturers on a variety of systems in development and coming into use. As the leading insurance and warranty provider for new homes, with 80 years at the heart of UK house building, NHBC is committed to supporting the industry to develop new construction methods that deliver quality new homes that will perform well over many decades to come, satisfying the needs of home and asset owners, investors and mortgage lenders.

2 We take a rigorous approach to checking that these requirements have been complied with, both in the design and specification, but also in the onsite construction and assembly. By doing so, we can be confident in providing warranty and insurance against structural defects – the assurance required by lenders and investors, and the protection needed by home and asset owners. Traditional and Modern Methods Whilst a large proportion of the homes registered with NHBC over the past 80 years have been masonry, we have accepted many other types of construction. In the 1970s we witnessed fast growth in the use of timber frame – the MMC of its time – and supported the industry by developing robust technical guidance, which went onto form the basis of Chapter 6.2 of the NHBC Standards, ‘External timber framed walls’.

Similarly steel frame construction was gathering momentum in the early 2000s, a form of construction that we embraced through Chapter 6.10, ‘Light steel framed walls and floors’, which was published in 2005. Over time, we have seen a range of systems and components coming to market – some more successful than others. We have witnessed unforeseen issues with finished homes and we learn lessons from the issues we view during inspections on site and from claims for structural defects. Data collected from our onsite inspections and claims is constantly analysed and fed back to facilitate continuous improvement and updating of NHBC Standards, which ultimately benefits homebuyers. This ‘virtuous circle’ enables NHBC to evolve housebuilding Standards to accommodate emerging issues and new methods.

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We work best when we are involved at an early stage. Our technical teams will work with manufacturers and housebuilders to review their overall programme from component materials and design to onsite installation and connection, to ensure the whole building is constructed to meet NHBC Standards and is acceptable for NHBC Buildmark warranty and insurance cover. For more details of our approach to MMC, and the systems and components already accepted by NHBC, please visit: www.nhbc.co.uk/mmchub This website also enables manufacturers to submit their products for review.

3 Images: 01-03. NHBC is currently working with many designers, housebuilders and manufacturers on a variety of offsite systems

ILKE HOMES

A GLIMPSE OF THE FUTURE? Lee Newman, Chief Executive of offsite building specialist Elliott, explains why the next generation of offsite-assembled homes is surprisingly traditional in design. plant can have capacity for over 500 homes per year, customised to client specifications. Local plants offer economic development, employment and training opportunities, in addition to physical regeneration.

1 First time buyers have had limited access to the quality advances brought by offsite assembly. Even when the product has been attractive to them, location and mortgageability have got in the way. What the market demanded was a mortgage-able house, with an instant kerb appeal to first time buyers. Rolling that out nationally needed a scalable business model, relationships across the UK and the flexibility to look at home whatever the local vernacular. ilke Homes has been established as a joint venture to provide precisely that product. This partnership brings together Keepmoat Homes’ expertise in homebuilding for first time buyers and partners, such as local authorities and housing associations, with Elliott’s expertise in offsite construction across a variety of archetypes for commercial and public sector use. In fact, the ilke Homes product is tenure neutral, as it needs to be to work on one of the UK’s typical mixed tenure sites, where receipts from private sale homes cross subsidise affordable tenures. The product can adapt to landlord specification or local design standards through a choice of four chassis sizes and flexibility on internal layouts. It efficiently forms two-three storey terraced or semi-detached houses or low-rise apartments. As an example, the

two-storey, 80m2 home can be both a Nationally Described Space Standard compliant two-bedroom, four person home for social or affordable rent or a three bedroom, five person home with master bedroom en-suite shower room for open market sale and private rent. For housing associations and local authorities the product and business model offer an affordable way to align development of high performance homes of all tenures with policy incentives to use modular construction. They offer speed of completion, lack of reliance on limited construction labour and ability to get around obstacles on stalled sites. They can provide new homes alongside existing buildings, unlock small infill sites and accelerate estate regeneration. Speed of completion is remarkable. ilke Homes’ precision-engineered modules leave its assembly plant at Carnaby in East Yorkshire fully finished, to be installed at the rate of up to ten homes per site per day, allowing a street of homes to be installed in a week and saving as much as six months on a 50-home development. The ilke Homes partnership will scale up to meet demand by opening a second UK assembly plant within a year and offer a series of ‘clone’ plants local to major sites. Each assembly

This is not a design that shouts about its credentials, but it is nonetheless a high performance home and for the same cost as a traditionally built home. Houses and flats from ilke Homes are quiet, airtight, super-insulated and with running costs one third cheaper than traditionally built brand new homes. An upgrade to zero carbon homes standard with the addition of factoryinstalled solar photovoltaic panels, takes running costs to as little as £100 per year, less than one tenth of those for the average UK home. Under the skin is a hybrid of timber and steel construction. A steel frame gives precision to the structure. External insulation provides a thermal bridge free ‘warm frame’. Partially ventilated external wall cavity construction with an airtight breather membrane enables any moisture to escape from the structure. The consistent quality of the product is evident in its mortgageability, achieved through BOPAS approval and 10 year structural warranties from Building Life Plans or LABC, accepted by all major lenders. The key to the success of any modular solution is to have it fully designed for manufacture. What ilke Homes does so well is in combining that basic standardisation with sufficient flexibility to meet landlord and market requirements. For more information visit: www.keepmoatcorporate.com www.elliottuk.com Images: 01. The ilke Home is a hybrid timber and steel modular building with a high level of finish

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

CASE STUDY

HEALTHCARE

MODULAR CONSTRUCTION HEALTHCARE’S IDEAL MATCH

1 Matthew Goff, Director of UK operations at Actavo | Building Solutions, explains why the capabilities of offsite construction weigh in favour of healthcare facilitators across the UK. As patient-led demand grows, healthcare environments are continually looking to adapt and expand their facilities quickly and cost-effectively. The healthcare sector doesn’t have the time or resources to commission lengthy construction programmes and reflective of this, the NHS new construction framework has been created solely for the supply of modular buildings. The NHS £750m, four-year construction framework has been split into 11 lots. Actavo, along with the other successful contractors, will act as the principal contractor and will provide a wide range of services – from full architectural design for the initial concept, to services, site works and completion of bespoke modular buildings, modular healthcare units and modular education units. Promoting faster, cheaper and greener building solutions, the new framework has been awarded entirely to specialist, modular construction

contractors. As well as keeping expenses to a minimum through its fast-track modular construction methods, medical offsite buildings – including patient wards, theatres, A&E department and cleanrooms and many more – can be designed, built and delivered in weeks, reducing the pressure on bed availability and the need for short-term hire. From initial works to completion, it takes up to 67% less energy to produce a modular building , compared with a traditionally-built project. Whilst initial, onsite ground works are being completed, modules – which make up a modular building – are manufactured offsite, in a controlled, factory environment. Pre-fitted with electrics, plumbing, heating, doors, windows and internal finishes before they are taken to site, modular buildings are now also installed with energy-efficient systems such as PIR sensors, enhanced U-values and solar panels. Not only is the offsite manufacture greener, buildings are also designed to be energy-efficient for their entire life cycle.

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When you build offsite, you plan and construct with meticulous precision. It takes strategic thinking and rigorous co-ordination, but modular construction allows for minimal disruption to staff and patients which is particularly key in the acute care environment. Offsite construction also allows for a 90% reduction of the total number of deliveries to site as well as reducing up to 90% of waste generated as the structure is recyclable. NHS bed availability is at an all-time low, but offsite building techniques are the NHS’s construction dream. Modular buildings can be delivered up to 50% quicker than traditional methods, which affords healthcare establishments a degree of certainty in meeting their needs quickly and efficiently. Although initial costs are comparable with traditional construction, the whole-life efficiencies weigh in favour of offsite. Modular buildings can be designed and built to meet the same medical standards as traditional construction including Health Technical Memoranda (HTM) and Health Building Notes (HBN). In a medical environment, a construction team must remain vigilant in following strict infection control protocols. By using controlled, modular methods of construction, particular attention can be afforded to reducing the spread of dust, especially where immune-deficient patients are being treated. For more information visit: www.actavo.com/buildings Images: 01-02. Modular buildings can be the answer to many healthcare building issues

BOO! T H AT â&#x20AC;&#x2122; S N OT A S S CA RY A S L E AV I N G YO U R P R O P E RT Y I N V E ST M E N T U N P R OT E CT E D !

P R E M I E R G UA R A N T E E . C O. U K MD Insurance Services Ltd is the Scheme Administrator for the Premier Guarantee range of structural warranties. MD Insurance Services Ltd is authorised and regulated by the Financial Conduct Authority.

CASE STUDY

HEALTHCARE

OFFSITE MILESTONE FOR LANDMARK FACILITY As with all of Icarus LSF’s offsite projects, it was important that all supply chain partners were aligned at every step of the project. An initial supply chain workshop was used to ensure all parties fully understood the complexities of the project and the client’s requirements and this was followed by regular checkpoint reviews where time, cost, quality and risk were reviewed in collaboration with all key supply chain partners. Information management at every step of the project value chain was key – ensuring the effects of any late architectural or design changes were managed and the effect of any site risks or constraints were understood by all parties.

1 Working with Interserve and healthcare client Proton Partners International (PPI), Icarus LSF designed, manufactured and installed a full load-bearing light gauge steel solution for the construction of one of the UK’s first Proton Beam Therapy Units in Northumberland. The unit will offer a comprehensive range of cancer treatments to patients, being the first in the region to offer high-energy proton beam therapy. As a highly innovative provider of healthcare solutions, PPI wanted innovation to drive the highest possible performance in their construction project – which led them to approach Icarus LSF to ensure the building could rapidly deliver a highquality solution. Using pre-boarded light steel frame (LSF) wall panels, floor lattices and roof cassettes, Icarus LSF enabled the technically and architecturally complex building to benefit from a 40% programme improvement when compared with traditional methods, meaning valuable cancer treatments can now be delivered to patients much sooner than originally anticipated.

The unit included two storeys of loadbearing light gauge steel frame with steel stairs and lift shafts provided, with the LSF construction method enabling installation to continue in all weather conditions. The accelerated programme and rapidly weathertight system enabled follow-on trades to rapidly progress their works, contributing to significantly reduced prelims and a faster ROI for the end client. The project fell in line with Icarus’s A+ Green Guide rating, as well as its zero waste-to-landfill policy, whilst also delivering against the project’s BREAAM requirements. The warmframe nature of the solution meant that the building benefited from U-values significantly exceeding requirements. Full BIM models of the engineered solution were created using bespoke CAD software and linked directly via computer aided manufacturing (CAM) and computer numerical control (CNC) to high tolerance rollforming machinery. Panel assembly was de-skilled using machine-applied dimpling to remove the need for human interpretation of fabrication drawings.

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

To manage the flow of information and ensure alignment of the supply chain, a dedicated project management team was allocated to the project, ensuring each supply chain touch-point had a single point of responsibility within Icarus, who could then act as a conduit of information to and from the client team. This collaborative and highly controlled approach gave all parties continued confidence throughout the project that the supply chain was combining to deliver the most cost effective and speedy solution for the ultimate client. The client played a leading role in choosing offsite as a key construction method with Icarus LSF’s design, manufacture and installation subcontract successfully completed, on-time and well within the required programme. For more information visit: www.icarus-lsf.com Images: 01. Light gauge steel frame and offsite manufacture are at the centre of the UK’s first Proton Beam Therapy Unit

CASE STUDY

HEALTHCARE

PRECAST VISION FOR ALDER HEY Reinforced concrete ‘twinwall’ shear walls (approx. 1545 panels) to resist lateral loads, were located around lift shafts, stair cores and at strategic locations. These walls consisted of two panels of precast reinforced concrete joined to each other via lattice girders and infilled onsite with insitu concrete to create virtually monolithic concrete walls.

1 Alder Hey Children’s Hospital is the only hospital in a park in Europe and sets a new benchmark for the delivery of modern healthcare for children. The purpose-built £250 million development is one of the most ambitious medical construction projects ever undertaken in the UK. This sustainable, world-class hospital for children and young people treats 275,000 patients every year and features 16 digitally enhanced operating theatres and 270 beds. The new 45,000m2 building replaces the Victorian facility next door which will now be demolished, recycled and transformed back into parkland. This innovative, ground-breaking project involved the true integration of engineering and architecture and a huge amount of collaboration between the partners involved. The forwardthinking project team wanted to create a new paediatric medical facility to provide top-quality healthcare in an environment designed to enhance the recovery of patients. Bespoke, flexible designs were used to create sustainable, energy-efficient solutions throughout the building. Low environmental impact construction methods reduced waste to landfill and the use of high-quality, durable products lowered maintenance requirements and increased fire resistance.

2 To reduce onsite labour and improve health and safety, over 15,000 components for this six-storey building were designed to be manufactured efficiently offsite. These elements reduced the build time, contributing to what was Laing O’Rourke’s fastest hospital build – completed in 130 weeks and 20% faster than any previous healthcare project. Based on cost, efficiency, sustainability and design adaptability, the optimum construction technique for the structural frame proved to be a precast composite flat slab, supported by precast columns on a typical 8.1m x 8.1m grid. The perimeter facade was integrated with approximately 1,265 precast concrete load-bearing sandwich panels, designed to look like the red sandstone rock strata prevalent in Liverpool. These panels distributed loads to the foundations, removing the need for conventional columns and consisted of 200mm loadbearing solid concrete with 100mm rigid insulation and 100mm concrete architectural facing panel. Principle columns were designed by WSP | Parsons Brinckerhoff and precast offsite by the specialist sub-contractor. The suspended upper floor slabs were constructed of 350mm thick two-way spanning precast composite (filigree) slabs enabling clear spans over the concrete frame and reducing the overall building height. The slabs generally consisted of insitu concrete topping (275mm thick) cast upon 75mm thick precast concrete units fabricated offsite.

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The use of Design for Manufacture and Assembly (DfMA) was crucial to the speedy delivery of the hospital, with over 15,000 components built offsite, ranging from a lattice plank floor system, twinwall cores, precast concrete columns and preglazed external panels from the Laing O’Rourke Explore Industrial Park. Digital engineering was also an essential factor in the speed of information transfer between the design team and the manufacturing facilities. This was particularly pivotal in the co-ordination with the site team and Explore to design and track more than 12,000 precast elements, including the facade panels which give the building its distinctive character. Each component had a unique place within the construction sequence, so constant reference to the digital model and corresponding transport logistics were essential for the construction methodology. The distinctive appearance of the facade demanded a very complex manufacturing and delivery process and the components were also one of the largest sandwich panels ever produced at Explore, due to floorto-ceiling height requirements. The patient windows were specifically designed at children’s level, opening out onto the park with all departments looking over gardens or parkland, the hospital is flooded with natural light. For more information visit: www.laingorourke.com www.wspgroup.com Images: 01-02. Liverpool’s iconic children’s hospital is being totally transformed via a DfMA approach. Courtesy WSP | Parsons Brinckerhoff

HEALTHCARE CONFERENCE & EXHIBITION Birmingham 20 September 2017 This one-day conference and exhibition will create a platform for clients and their professional advisers, contractors and project managers to network with industry experts and discuss the latest offsite construction solutions that will help to deliver the building requirements of the healthcare sector.

SPEAKERS INCLUDE REPRESENTATIVES FROM:

WHO SHOULD ATTEND? The event is aimed at attracting construction clients; estates managers, local healthcare authorities, construction professionals: architects, surveyors, engineers; facilities managers; building product manufacturers and suppliers.

TICKETS

Ticket prices - £125 + VAT 20% EARLY BIRD DISCOUNT

…& many more!

Available until 01 August 2017. To book this discount, enter promotional code EARLYBIRD20 when booking online at www.exploreoffsite.co.uk/book

If your organisation has an innovative and pioneering offsite healthcare project or technology that you would like to share as a conference speaker, contact Grace Baker on

grace.baker@radar-communications.co.uk

To book your place go to www.exploreoffsite.co.uk/book

ADVERTORIAL

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

ADVERTORIAL

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

CONCRETE

CHAMPIONING PRECAST

Precast concrete is in prime position within the construction industry and is one of the key materials in the offsite mix creating exceptional landmark buildings. Along with our front cover story from Creagh Concrete this issue, over the next few pages we offer two exceptional facade projects from the Best Use of Concrete category at the Offsite Awards 2017. Firstly, at the University of London, where a number of building facades were manufactured offsite as composite precast brick faced panels. Secondly, we hear more about the distinctive architectural precast concrete facades at the Victoria Gate Arcade and John Lewis Partnership Department Store Development in Leeds. Special mention must also go to Kier Construction who won the hard fought Concrete category with its work at Broadmoor Hospital – there will be a full case study in the next issue of Offsite Magazine – where three precast ward buildings, central therapy building and entrance building have been built using over 6,000 components in a precast concrete frame with a large proportion of the mechanical and electrical (M&E) services cast within the panels. This project at one of the UK’s internationally known high-security 48

psychiatric hospitals was a complex and hugely successful command of precast concrete and offsite delivery. Kier Construction have also been involved with Project Capella – an £80 million 18,000sq m biomedical research laboratory for the University of Cambridge. Located within the Cambridge Biomedical Campus, the research facility had to meet strict environmental and vibration criteria. The result is a unique hybrid of precast and in-situ concrete with 80% of the frame and facade built offsite as precast modules. Six upper floors comprise precast columns, edge beams and precast floor slabs with an in-situ structural topping. This approach has reduced the delivery programme, allowing construction to start earlier and Project Capella was transformed from blank piece of paper to an enclosed building in 24 months. According to the Mineral Products Association and British Precast, the UK precast sector has an annual turnover of £1.3 billion and directly employs 13,000 people in the UK. The recent report from the Construction Industry Training Board (CITB): ‘Faster, Smarter, More Efficient: Building Skills

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for Offsite Construction’, explored attitudes and habits of those in the construction sector and asked about the use of offsite-specific construction materials and products. When asked the question: ‘Of the types of offsite construction materials and products used on your work, do you expect the level of use over the next 5 years to increase, decrease or stay the same’ - an amazing 100% of respondents say they expected the use of precast concrete panels to increase, with 91% anticipating the use of precast concrete frame to rise – you can read more on the CITB report on page 75. It is fair to say that market share of precast concrete and interest in its applications are higher than ever. For more information visit: www.concretecentre.com www.britishprecast.org www.concrete.org.uk Images: 01-02. Precast concrete has become a pivotal material in the hotel and student accommodation sector. Courtesy FP McCann

ARCHITECTURAL & STRUCTURAL SOLUTIONS SALES@FPMCCANN.CO.UK FPMCCANN.CO.UK

At FP McCann, we believe in working with you as a partner from the start, which means offering our expertise in designing and manufacturing rooms to suit every individual project. Far from being an off-the-shelf solution, our architectural and structural solutions are made-to-measure, whilst maintaining our design philosophies and standard details. All units are manufactured

off-site at our state-of-the-art Grantham and Byley depots and delivered to site, ready for final preparation and decoration. Our precast concrete crosswall construction is a fast and convenient way to produce multi-unit structures such as hotels, education, student, secure and health accommodation, private and social housing in a fraction of the time of traditionally built structures.

CONCRETE

PERFECT PANELS FOR UPP In partnership with the University of London, University Partnerships Programme (UPP) appointed a project team to redesign the existing student accommodation at Garden Halls. This included an innovative, eye-catching new precast facade. The entire (4,500m2) brick facade facing Cartwright Gardens as well as many of the other facades were manufactured offsite as composite precast brick faced panels. This was implemented as an approach to offer construction programme efficiencies and advantages, such as robust programme, guaranteed quality assurance as the panels were constructed in factory conditions, a reduction in safety critical activities meaning a reduced number of operatives working at height plus reduced disturbance to neighbouring residence and businesses due to an omission of the perimeter scaffold. Designed by executive architect, tp bennett, in partnership with Maccreanor Lavington, who was the architect for the principal facades, the new £140 million, 59,831sq m scheme provides the University with a 18% net increase in capacity, which amounts to an additional 187 beds. The new buildings repair what was a fragmented urban block and deliver a scheme that respects its historic 50

context. A key challenge to construct a contemporary nine-storey facade along one side of an historic garden square was delivered using specific offsite construction methods to maximise efficiencies and minimise waste. The facade was built in three zones beginning with the north end of the building and moving to the south. In each zone, the lower three-storey piers were erected first, then the spandrels and sills slotted in. This process was repeated up the building with the three-storey T-sections followed by the two-storey T-sections. Finally, the mansard sections were lifted into place together with the two-storey dormer windows. The piers and T-sections bear all the weight back to the ground. These elements were stacked on top of each other and restrained back to the buildings’ reinforced-concrete frame at the top of each section. The spandrels and sills were bolted to the piers on either side. This meant that the reinforced concrete frame only takes the horizontal loads from the facade, so it’s a lot thinner than it would have

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been if it had to also support the weight of the precast panels. The only element supported by the reinforcedconcrete frame is the two-storey mansard. The prefabrication allowed the design team to develop stepped brick details that make reference to the detailing of traditional load bearing masonry. The depth of the facade also allows it to be constructed from large load bearing units, which require fewer movement joints than contemporary site laid brick cladding. This delivers a building with a more monolithic character akin to traditional masonry while minimising the amount of onsite labour. The overall development was delivered to budget within a tight 26 month programme and has a BREEAM Excellent rating. Early in the design process Maccreanor Lavington suggested brick-faced, precast offsite construction be adopted for the main Cartwright Gardens facade. This approach was later employed for the other brick

CONCRETE

1 facades on Leigh Street and the townhouses on Sandwich Street by TP Bennett, which varied in height from five to four storeys. One of the reasons for choosing offsite was because of the amount of stepping in the elevation. The stepped soffits would not be easy to make onsite and would be very time-consuming and craftsmanshiporientated. There was also a time pressure. If built conventionally, the programme would take much longer, would be less precise, more expensive and would need scaffolding and the quality achieved with offsite manufacture would not be easily replicated if built insitu. The offsite techniques and refinement of the technology has allowed something quite crafted, such as the steps and reveals, to be created in a monolithic way. The brick elements are load-bearing to the ground and without massive joints in between, giving the brick an almost stone-like, carved appearance.

4 Over the course of the project UPP and the University of London has engaged and managed circa 150 subject matter experts in design, construction, finance and operations. The culmination of effort developed a market-leading offer in central London that has embraced offsite construction. As a major project, collaboration, quality and a drive to create legacy during delivery and beyond have been the drivers across the lifecycle. The successful contractor Multiplex brought with it a wealth of experience building in sensitive central London locations, and experience of delivering student accommodation. They employed the specialist subcontractor Thorp Precast to design, manufacture and install the different precast elements of the facade in an efficient and low impact way. Garden Halls is now one of the largest and most responsive student residential developments in London, providing 1,200 rooms that consider the diversity of todayâ&#x20AC;&#x2122;s students and

cater for all living requirements, including townhouses and cluster flats. It has been developed sensitively, closely engaging with key stakeholders such as English Heritage and the Bloomsbury Conservation Area Advisory Committee (CAAC). The use of offsite construction has delivered this important project that offers exceptional architectural quality and modern higher education facilities. UPP are involved in a several large student accommodation projects and are looking at adopting a range of offsite construction methods in the future, including the use of precast solutions, reflecting the positive outcomes of the project. For more information visit: www.tpbennett.com www.ml-architects.com Images: 01-04. Garden Halls has benefited from a striking architectural precast facade. Courtesy Maccreanor Lavington

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CASE STUDY

CONCRETE

PRECAST LEEDS THE WAY

The Victoria Gate Arcade and John Lewis Partnership Department Store Development in Leeds has one of the most distinctive architectural precast concrete masonry facades seen anywhere in the UK. The purpose of the project was to create a whole new shopping experience in the centre of Leeds, linking the old Victorian Quarter via a high-quality shopping arcade leading to the entrance of the new flagship department store and car park for John Lewis Partnership. Thorp Precast were appointed by main contractor McAlpine for their expertise in precast brickwork cladding to carry out all the ornate precast brickwork, terracotta and recon stone facade panels featured on the new Victoria Gate Arcade, whilst Techcrete were hand-picked for the elaborate reconstituted stone precast concrete cladding panel for the new John Lewis Partnership Department Store. The 6,000sqm brick facade pattern features six different width pleats, each having a 250mm overall projection, by way of a modern reference to Leeds rich Victorian past for corbelled and highly decorative brickwork. The North Block features white recon stone columns with an acid-etched finish at ground floor level with brick-faced panels above and white recon pier infills.

The South Block has black recon stone columns with a polished finish at ground floor level, with brick-faced panels above. Most of the cladding panels were designed by Thorp Precast with an emphasis on stacking the panels meaning only restraint was taken off the primary structural frame, with all the dead loads transferred directly into the foundations.

The principle reason for choosing offsite was because of the amount of intricate stepping and complex geometry in the various Victoria Gate Arcade facades. The decorative reveals and soffits would not be easy to form onsite, being extremely time consuming and craftsmanship orientated. The use of offsite allows a far greater degree of control over the quality and accuracy of the elaborate architectural details and interfaces.

BIM technology played a fundamental role in helping create the complex angular 3D panels in brick, terracotta, and recon stone panels. A range of other potential cladding solutions were considered by the design team, including traditional handset brickwork, numerous brick slip systems, even bricklaying robots at one point, before precast emerged as everyone’s preferred option. The intelligent and efficient use of precast concrete was fundamental in producing some of the most complex geometrical architectural masonry precast cladding panels ever undertaken in the UK, with 550 largely unique panels, designed, manufactured, supplied and installed seamlessly onsite, on time and all within budget. The use of BIM technology to help design the 3D masonry facade was also instrumental in achieving the unique architectural design intent.

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It’s extremely rare to find such a large scale development featuring a full range of materials using precast concrete, showcasing different manufacturing techniques, complex panel geometry, 3D mould capability, BIM design technology, such crisp panel alignment, general workmanship and quality of finish. Without the use of concrete it’s highly unlikely the façades could have been built in their current form. Whilst other methods of construction were considered it was clear from the outset that the use of precast concrete and offsite technology provided the confidence, certainty, integrity and affordability the client was seeking in this landmark development. For more information visit: www.thorpprecast.co.uk Images: 01-03. Precast concrete has proven to be an exceptional architectural addition. Courtesy Thorp Precast

5257_K2000_Adv Offsite magazine_w190h127mm_UK_v4.indd 1

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STEEL

STANDARDISATION IN MODULAR CONSTRUCTION: POSSIBLE OR DESIREABLE? A key strength of offsite construction rests in its repeatability and standardised set of components but as Mark Lawson of the Steel Construction Institute (SCI) explains, ‘standardisation’ can have various meanings in the construction sector. From a use of components from a ‘kit of parts’, agreed dimensions for planning, use of a common range of connections and details, and conformity of design to industry standards, standardisation can mean many things. In the context of modular construction in which modules are essentially unique to one manufacturer, the questions are: ‘what does standardisation mean’ and ‘would standardisation offer advantages to the consumer and the supplier?’

Manufacturers of modular systems have their own range of components, dimensions, connections and methods of assembly, so it the starting point for standardisation is already difficult technically. It is also not desirable from a supplier’s point of view to offer a system that can be replicated by others because of the need to work closely with the client’s architect during the design phase well before manufacture starts.

Modular construction is more developed in the UK than in other countries and the main reasons for this are a vibrant economy where clients value speed of completion in terms of the business benefits that it offers, and the manufacturing economy of scale that is possible in sectors that require essentially cellular space. Hotels, student residences and military accommodation are the well-known sectors where modular construction has proved to be popular and where these benefits are readily quantifiable.

Therefore, standardisation in the context of modular construction would only be of benefit if it leads to significant market growth outside the more conventional markets for modular systems. For example, the production of dimensionally standard modules ‘to stock’ could lead to markets for ‘off the shelf’ modular units particularly aimed at small contractors or self-builders. This would have to be seen as beneficial to the industry and should lead to new market opportunities rather than usurping existing hard-won client relationships.

Educational and medical buildings fall into another group of modular systems where open space is required and where the offsite installation of equipment and services leads to improvements in quality and reliability, which again have tangible benefits. These sectors also have strict performance standards, and the modular companies active in these sectors have a high level of technical ‘know how’ to meet these demanding requirements.

Any drive towards a greater level of standardisation is more likely to come from the consumer and particularly from strong client groups if their ‘buying power’ can influence a coming together of the industry and users. Client groups who could facilitate change are consortia of social housing providers, Local authorities and Government (if they become procurers of housing) or the NHS.

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Portakabin has already produced an excellent starting point with its range of standard module sizes. Let us explore what standardisation might mean in the context of a new generation of modular construction: • The combined wall width and floor/ ceiling height of a new modular system could be dimensionally standardised for ease of planning and design. Combined wall widths of 300mm and floor/ceiling heights of 450mm would seem to be sensible for four-sided modules. This would include nominal gaps between the modules. • The internal and external dimensions of modules could be standardised for the general market. Based on a 300mm planning grid, a 3.6m x 7.5m module internally would be 3.9m wide x 7.8m long externally. This size of module is suitable for transportation on the main road system. • A 2:1 aspect ratio of the module would allow for re-orientation of the modules i.e. one module could cross the ends of two other modules to form larger spaces. Module configurations that conform to this discipline are: 3.9m x 7.8m, 3.6m x 7.2m and 3.3m x 6.6m in external dimensions. • The standard module height could be adopted as 3m externally and 2.55m internally, which is also a multiple of brickwork dimensions. • Four-sided modules should be designed with facility for partially open sides of a minimum of 2.4m opening width to allow two modules to form one larger unit. • The module connection points should be standardised in order that modules can be lifted and re-used without specialist equipment. In a large project or a series of similar projects, modules could be moved or replaced. Lifting points and connections should be bolted and accessible after the building is completed.

STEEL

1 • Floors and ceilings should be joisted, but it may be necessary to offer a concrete floor option with the same dimensions for certain markets. The floor joists would be typically 200mm deep and ceiling joists may be 150mm deep. • Balconies and external walkways should be connected to the corners of the modules that are accessible in the future. Re-entrant corners to modules or square hollow section post with projecting fin plates are two solutions. Cantilever balconies require additional posts that are tied into the modules. With these design and manufacturing features, would the ready availability of say 3.9m x 7.8m modules encourage architects and builders to think of designing using these large ‘building blocks’ rather than designing a bespoke solution? If the market opportunity was compelling, would manufacturers agree to offer these standardised solutions with short lead times by investing in more automated production? The use of old shipping containers in hotels and student residences is a kind of ‘forced’ standardisation through their relative low cost and fixed dimensions, although they are not suitable for general application. But their use does show that low cost and availability are drivers which can overcome other disadvantages.

The following arguments for the savings that accrue from use of more standard module configurations for some types of projects are: • New markets for smaller projects would be created, such as extensions to existing buildings or small residential projects. • Design and setting up and procurement costs are greatly reduced. • Manufacturing of the basic fabric of the modules can be done in ‘downtime’ between larger projects, which means that the factory is more efficient in terms of productivity. • Greater guaranteed production would encourage greater investment in manufacturing facilities.

In terms of design standards, there is no industry standard for modular systems, although a building Code is being developed in Australia. A greater level of standardisation among modular systems would encourage development of this Code. The Steel Construction Institute is a in a good position to do this having produced many publications on modular construction and light steel framing. For more information visit: www.steel-sci.com or feedback comments to Mark Lawson at email: m.lawson@steel-sci.com

Images: 01. Offsite Modular Frames Courtesy of EOS Facades

• Costs to the consumer would reduce significantly depending on the output rate. • Lead in times would be greatly reduced and ‘off the shelf’ modules could be delivered rapidly. • A common design standard would be prepared for the new modular system, which would reduce client costs. • Savings of 10 to 15% over more conventional site-based construction would be compelling when combined with the obvious speed on construction benefits.

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CASE STUDY

STEEL

STEEL FOR BATH ROAD

1 Arts University Bournemouth has more than 3,000 students and is growing each year. Metsec’s Metframe provided the perfect offsite solution to create new halls of residence and meet extra capacity for the future. Identifying a need for additional student accommodation in the area, ASN Capital who act as both residential and commercial developers and landlords, had a plot on Bath Road in Bournemouth where it had planning permission to build a halls of residence. Delivering the project as the main contractor, ASN Capital wanted to maximise project efficiencies by sourcing the fewest packages possible. The footprint of the plot was small, and the planned building was complex, with a curved front facade and a staggered shape to the rear. ASN Capital selected Atkin Trade Specialists to deliver the installation and after reviewing the options, together selected Metsec’s Metframe as the offsite framing solution for the building. The Metframe solution is prepanelised offsite to reduce time onsite and increase the overall speed of build – ideal for ASN Capital’s ambition to complete the project as soon as possible. In fact, thanks to the speed of Metframe construction, the erection of the superstructure took less than 13 weeks, halving the time a standard build would have taken.

A major factor in reducing the time needed for the build was that in addition to the frame, the stairs and lift shafts were integral to the Metframe system and were installed as each floor was constructed. This removed the need for additional contractors to fit the stairs and lifts at a later date, and instead everything was completed concurrently using Metsec’s offsite solution. Having an integrated solution also meant a single point of contact for a significant amount of the build. Amir Sadeh, of ASN Capital, said: “Our priority was to move the project along swiftly and efficiently. We reviewed multiple solutions that were available to us and selected Metframe as it was ideal for what we needed. We had a small plot and a tight time frame and Metsec’s solution allowed us to deliver everything to deadline.” The 2,610sqm halls of residence at Bath Road has a concrete basement housing a communal room and bike store, a groundfloor including a lobby, built partially using Metframe, and eight storeys above ground housing all 84 en-suite accommodation studios for students, entirely built from Metframe Jeff Harris, from Atkin Trade Specialists, said: “The building is BIM-compliant, designed in a 3D environment which gave ASN Capital a very clear simulation of what each part of the building would look like.

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2 In using Metframe, with panels delivered to site in the required erection sequence, the project has zero waste therefore reducing the environmental impact. The overall quality and accuracy through designing in a BIM compliant project and using Metframe leads to material, time and cost savings. Having ASN Capital involved throughout and carefully reviewing the best solution for their project meant that they selected a time-saving and cost-efficient solution which gives high performance in terms of thermal, acoustic and fire protection.” The Metframe solution was able to withstand a concrete roof on the building, which future-proofed the building, allowing an additional floor to be added at a later date if desired. The Bath Road project used 77 tonnes of cold rolled steel and 15.5 tonnes of hot rolled steel. For more information visit: www.metsec.com Images: 01-02. Bath Road, Bournemouth

WEEKS

16 WEEKS

METFRAME

PRE-PANELISED OFFSITE BUILDING SOLUTIONS Fast • Efficient • Compliant • Sustainable Our Metframe solution is used to provide the load bearing superstructure for low to medium rise buildings. A major benefit of the system is its speed of build with Metframe structures typically taking under two weeks per floor to construct. *Speed of erection shown is based on an average 700-1000m2 floor area per level.

voestalpine Metsec plc www.metsec.com

metsec.com/steel-framing/metframe 0121 601 6000

STEEL

COURTING CURVES Wimbledon – home of the All England Lawn Tennis & Croquet Club – commissioned a new open/close roofing solution for Court Number 1. EOS Facades designed two walls to envelope the entire circumference of Court Number 1. The inner wall is onsite with the outer wall to be constructed after this year’s Championships.

Situated alongside the existing roof apparatus on Centre Court, EOS were appointed to deliver a fully inclusive service of design, supply and scheduling. EOS utilised cold formed steel sections in a highly unusual manner, designed to mask the support structure for the new roof mechanisms, creating a variable radius curved wall to be used as a support and screening structure. The design includes a range of features including: bespoke and highly resilient wind posts, bracketry stiffened with bespoke elements, as well as tall cantilevered solutions. The design will be produced using a full BIM package with all manufacture data being taken from the BIM model. The scope of supply included all ancillary parts and fixings.

Prater awarded this highly prestigious scheme to EOS following a number of successful project completions in which BIM Level 2 design capabilities have been partnered with their fully inclusive service to deliver a wide-ranging scope of supply and technical excellence. The project is in two phases. The first phase will introduce the main roof support structure and courtside finishes. This will be temporarily suspended for the 2017 Championships, with all cranes and signs of construction work removed from site. The second phase will return after the Championships and will involve finishing the installation of the roof structure and associated external works.

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The inner wall is court side and forms a striking curving structure which will hide the mechanisms of the new roof structure. This will be a lasting structure and integral to the internal aesthetics when the entire project is finished. The wall extends to the entire circumference of the building. The outer wall is part of phase two of the project and will hide the mechanisms from an external view point when fully completed. As with the inner wall, the entire stretch extends to the whole circumference. For this project, EOS has used predominantly standard cold formed C sections in a highly non-standard approach. A linear product has been adapted to form very large and variable radius facets around the perimeter on the inner side of the court. The EOS wall is essentially positioned in a void

STEEL

zone between the concrete head and base support footings for the new roof. The EOS steel frame creates a screen which has been tied back to available elements using bespoke wind posts at the base and stiffened oversail brackets to the head. All supporting bracketry has been supplied and engineered by EOS. The inner wall features a large vertical cantilever which will form the main screen ‘hiding’ the heavy infrastructure which is supporting the

on the scheme which will be left unfinished during the Championships. EOS provided all sections cut to length with compound sections preassembled in the EOS state-of-the-art factory where applicable. All elements were bundled and issued to site colour coded and with all parts individually labelled to match the design drawings to enable quick and easy location by site teams – resulting in significant reductions in time.

1 new roof elements. All elements have been BIM modelled to Level 2 and manufacturing data taken direct from the EOS 3D BIM model. EOS also coordinated fully with the architectural requirements of the screen down to the minutest of details – one example being, a void providing a precise location to allow for Hawkeye Camera Analysis to be positioned for the matches. The completion deadline of phase one of the project was definite, as Court Number 1 needed to be fully operational for the 2017 Championships, if not there would be a substantial loss of revenue – well in excess of £10 million. The EOS screen has been designed and delivered on time and to an extremely tight deadline. The EOS wall is integral to hiding the new structural elements

3 This scheme was priced as a ‘lump sum’ package – a standard EOS offering – allowing cost certainty during initial feasibility. By utilising BIM Level 2 modelling and design approaches – lead times are significantly reduced, meaning that manufacture and delivery slots were known and pre-programmed weeks in advance. EOS also applied Design for Manufacture and Assembly (DfMA) methods to this project. The DfMA process helped to identify, calculate and eliminate waste or inefficiency in the building design. This allowed the implementation of increased resource-efficiency, decreased costs and reduced need for onsite labour. EOS believes that sustainability is imperative to any construction project. The recycled content of the raw material is approximately 60-70%

allowing for significant reductions in environmental impact. The material is designed and supplied cut-to-length, there are virtually no offcuts to be made onsite which reduces wastage to small offcuts of steel to cater for minor site variances. EOS always design the most cost effective/lightweight solution, which is automatically determined at pricing stage based on wind load and section length. Transport is a key factor to consider in terms of environmental impact, the transport for this project was phased to make best use of just-in-time delivery and was co-ordinated with site requirements. The EOS sections provided are lightweight cold formed C Section Studs, which reduced the load on the foundations and supporting elements. They are easy to handle onsite and can be erected very quickly. The fact that the sections are pre-cut, enables upwards of 25% installation gains as well as being at least 50% faster than traditional build or heavy hot rolled steel systems. With EOS supplying all ancillary parts and providing cold formed studs/tracks cut to length – a very tight deadline has been achieved, permitting an incredibly fast erection. Site issues are non-existent due to the design being BIM modelled and being manufactured in factory controlled conditions with stringent quality checks. This was a unique project that allowed EOS to harness the benefits of offsite construction and take a linear product and form something highly irregular, whilst remaining simplistic in nature. A seamless curving wall fits well within the circular nature of the existing stadium. The architectural lines flow consistently throughout and do not draw on the attention of the crowd or tennis players. For more information visit: www.eos-facades.co.uk Images: 01-03. The striking architectural curving structure will be completed in two phases Courtesy EOS Facades

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

ADVERTORIAL

MODULAR CONTRACT MILESTONES

1 Caledonian Modular continues to build on its recent successes with a series of new orders totalling £70 million that includes a slice of the huge development of modular complexes at Hinkley Point C – the first in a new generation of UK nuclear power stations. The latest new contract announcement is a £50 million order to supply the construction workers with hotel-type accommodation units for the new Hinckley Point C nuclear plant. The contract guarantees Caledonian 15 months’ work designing and constructing the accommodation for the 1,500 workers, building the UK’s first nuclear power station in 20 years. Caledonian held an event recently at its 12 acre manufacturing site in Newark to mark the first of the accommodation modules leaving the production line. Supplied 96% complete, the finish includes tiling, wall and floor finishes with internal M&E. Significant benefits include their readiness for rapid commissioning onsite and minimising the impact normally associated with traditional building techniques on the community. Another huge advantage is via the external cladding being applied during the manufacturing process, enabling each 34-bedroom block 60

to be completed in six weeks once delivered to site. The accommodation is equivalent to a three-star rated hotel, which makes this contract the largest hotel development in Europe since Disneyland Paris. The offsite construction of the campus accommodation is managed by Caledonian in partnership with Laing O’Rourke. In a succession of major new business wins for Caledonian, the company also secured a £13.5 million new school dormitory for ACS Cobham, a prestigious international school based in the UK where Caledonian will act as concept designer and Principal Contractor. Other new contract wins include a £2.5 million project to deliver a new sports complex for Ashville College in Harrogate, with Caledonian acting as full turnkey contractor, including manufacture, delivery and installation of the new building as well as demolition and groundworks.

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Continued success at Caledonian is part of a strategic aim of reestablishing the company’s position as the leading manufacturer of permanent volumetric offsite buildings in a fast-changing construction environment. Various other new business wins and imminent orders take the total to over £70 million. Paul Lang, Chief Executive Officer at Caledonian, says: “With a strong management team, financial stability and a clear business plan for long term sustainable growth we are perfectly positioned to capitalise on an increasing awareness of, and reliance on, offsite construction techniques.” Caledonian is aiming to further bolster its order book by securing work from a number of strategic Frameworks that have been created primarily to serve the public sector. These include the LHC Modular Framework, the Southern Modular Framework and more recently inclusion on the NHS Framework. Moving forward the business will primarily focus its operations on three key market segments: Residential, Education and the Defence Sector and has plans to grow revenues to over £100 million over the next three years. Over the last eighteen months, the business has gone through a sizeable restructure. “We had to strengthen the team in a number of key areas,” adds Paul Lang. “We have brought in some high calibre individuals from across the construction and offsite sectors.” The company will be doubling the size of its 100 strong workforce over the next few months and has also relaunched its apprenticeship scheme. All new recruits are put through an intensive training programme at the company’s manufacturing site in order to ensure they have the necessary skills to maintain Caledonian’s reputation for high quality offsite building solutions. For more information visit: www.caledonianmodular.com Images: 01. The modular worker accommodation at Hinkley Point C is the largest hotel development in Europe since Disneyland Paris

Offsite construction expertise • Leading manufacturer of offsite buildings • Recognised industry-leading expertise • Principal contractor / designer, specialist subcontractor. 01636 821645 www.caledonianmodular.com

CASE STUDY

MODULAR MATTERS

APPLYING A BRICK FINISH WITH OFFSITE

A brick finish remains as popular as ever, particularly in British architecture, but what is the best way to achieve this for the offsite construction sector, without compromising critical speed of project delivery benefits? Richard Haines, Director at Eurobrick explains more.

With the skills shortage in the construction industry causing real concern, reducing the dependency on traditional skilled labour is beneficial. Our cladding systems can be assembled by semi-skilled labour, helping to ease pressures both in terms of finding workers and the associated costs.

Eurobrick was the first company to introduce a comprehensively designed brick slip cladding system to the UK, 27 years ago. The offsite construction and modular sectors have long recognised the benefits of cladding systems and Eurobrick has supplied a wide range of projects including schools, colleges, residential developments and restaurants throughout the UK.

We have also supplied our systems for many school expansion projects. The vast majority involve modular buildings and over the years we have worked with most major modular building companies. Our systems are suitable for both on- and offsite installation but often are installed once the modular buildings have been delivered to site.

Much of our early work was with McDonald’s Restaurants. During the early 1990’s they undertook a major expansion campaign in the UK, constructing hundreds of ‘drive thru’ restaurants in a short space of time. Our X-Clad system was installed on over 700 outlets and continues to be used in the current expansion programme. The majority of the buildings were prefabricated and factory built. Our cladding was also installed in the factory and the building then transported to site. X-Clad has an extruded polystyrene backer panel making it very lightweight, easy to handle and cut to size. In a controlled factory environment, an installer should be able to install at least 1sqm per hour.

Parkfields Primary School is an example where 135sqm of P-Clad was installed in the factory, taking only five days, using two installers and one pointer to fit the cladding and point the brickwork. Twenty four hours after the installation was completed the building was lifted and by the next day it had arrived onsite in Bedfordshire. The only onsite works required to complete the exterior finish was to insert the brick slips and point where the modular joints met. P-Clad comprises a cement particle board backer panel, developed by us to work as an external sheathing to a structure. This system is certified for installation on buildings over 18m high constructed using a steel frame substrate wall. Being able to use brick slip cladding on high-rise buildings is of particular interest at the moment,

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we have noted a marked increase in enquiry levels, especially for residential developments. The Point, Ilford, is a large residential development comprising one, two and three bedroom apartments. A substantial part of the building was constructed traditionally but some areas were finished with our P-Clad system. We supplied around 500m², excluding the brick slips which were sourced separately. The P-Clad system was constructed to include a draining cavity over an insulated structural wall. Sections of the development exceeded 18m high and as such required a cladding system suitable for this purpose. P-Clad was also used on a modular residential development in Liverpool, a new £3.5m development of 33 eco homes for Liverpool Mutual Homes. Our cladding was installed offsite allowing for greater quality control and speedy project delivery. A well-designed cladding system offers a level of product consistency that is essential to the offsite construction industry and vital for mass produced buildings. Eurobrick’s systems are certified by the British Board of Agrément (BBA) and are trusted by the offsite sector to provide durable, low maintenance brick slip cladding for its projects. For more information visit: www.eurobrick.co.uk Images: 01. The Point, Ilford 02. The X-Clad system was installed on over 700 McDonald’s Restaurants

QUICK, VERSATILE AND EASY TO INSTALL • Supplying off-site construction for over 25 years • Assists with speed of project delivery • P-Clad certified for use over 18m high • Robust, reliable, quality systems • Low maintenance with 25 year guarantee

0117 971 7117 www.eurobrick.co.uk

CASE STUDY

MODULAR MATTERS

STACKABLE AND REPEATABLE

Branded hotels as a building type are well suited to modular prefabrication because of the high degree of repetition. With the rectangular plan form of two simple linear bedroom blocks linked by a striking glazed walkway, as well as bedroom windows centrally located in the external wall, the project was ideally suited to modular. The ground floor bedrooms, not being as tall as the adjacent transfer deck presented an engineering challenge to the stackable solution but careful co-ordination and planning of the steel spacer frame to ensure all first floor bedrooms.

1 The New Hampton by Hilton hotel at Bristol Airport was the 50th Hampton to open in the UK, in early 2017 and the success of the scheme was largely attributed to the use of volumetric bedrooms built using containerised technology. Architects Stride Treglown worked with China International Marine ContainersModular Building Systems (CIMCMBS) engineers in London and China to manage the modular fabrication design development, co-ordinating the structural and mechanical and electrical bedroom areas design for a UK project built by Kier Group. The entire 201 bedroom hotel was assembled in less than four weeks, allowing the bedroom areas to be 95-98% complete when the entire construction project was only 50% built. By embracing a modular solution, the design and fabrication of the bedrooms ahead of construction starting on site means that projects could be delivered with a 20-30% saving on programme. The high quality of bedroom finishes achieved as well as the generous public areas at ground floor have delighted the client and operator alike. The bedrooms arrived ready fitted out according to the hotel brand’s exacting requirements, including finished bathrooms, beds, chairs, casegoods, equipment and floor and wall coverings, sourced in China.

The use of a container-build bedroom solution was decided before the hotel secured planning approval which delivered the best results for modular design and for the owners, who are the parent company of the modular system. Early engagement with the modular supplier is a key factor in making a success of modular systems, coupled with a hotel design of two simple rectangular bedroom blocks linked by a glazed corridor on three levels. The 201/251 phased design allows for an additional 50 bedrooms to be added to the hotel as passenger numbers and hence hotel occupancy increase – an ideal build solution for a hotel to remain trading for the duration of the fast-track installation. The facade cladding solution was also adapted to suit the module structure, making use of longspan aluminium composite panel solution to achieve an insulated and watertight facade as soon as practicable. The facade treatments were then applied over this external skin. The typical volumetric module consists of a bespoke section through the building – a completed bedroom/ unfurnished corridor/ completed bedroom that are stacked and bolted together onsite in a matter of weeks, designed according to the exacting hotel chain brand standards with consistently high quality finishes. CIMC as container modular provider were also the developer and owner of the final scheme.

The development and use of BIM has assisted the volumetric supplier in their manufacturing sequencing. The main contractors build sequence is in reverse to the factory production and the use of 3D software has aided CIMC with their craned elements installation onsite – assessing loads and forward logistics planning. The BIM element enables early resolving of traditional interfaces e.g. with the in-situ blockwork lift shaft within a module, as well as coordinating the distribution of services within the ever-shrinking bathroom risers. The factory based designers in China draw every aspect of the container fabrication and fit-out for approval by the UK consultant team. No drawing/ schedule can be fabricated without Construction status ‘A’ sign-off. Where products have been selected from a Chinese or Australian supplier, they are still required to meet British and European Standards, with certification. Each hotel project/ configuration requires new solutions. Our CIMC Hampton Docklands required corner windows, trapezoidal rooms and an onerous fire protection strategy, all resolved with factory based-design. The benefits of container modular volumetric are still evolving in the UK market. CIMC continue to develop their own use of BIM in designing and procuring their modules, and the Bristol project illustrates the importance of choosing a rectilinear building with a high degree of repetition. For more information visit: www.stridetreglown.com www.cimc-mbs.com Images: 01. The repetitive modular approach lends itself easily to branded hotels. Courtesy of Stride Treglown

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INDUSTRY MUST EMBRACE NEW TECHNOLOGY TO THRIVE Building Information Modelling (BIM) can deliver untold benefits to the construction process and provide huge benefits to the entire supply chain. Alex Goodfellow, Group Managing Director of Stewart Milne Timber Systems (SMTS), gives his view on why embracing BIM is more important than ever.

One of the major changes to the construction industry in recent years has been the introduction of BIM which is a collaborative digitally enabled design and construction process which uses 3D modelling to deliver a project, across multiple professions and trades, from concept to facilities management. Historically the construction industry has been one of the least digitised sectors, relying on traditional design and construction methods to deliver projects. However, in recent years this has started to change with the industry accepting that to deliver projects in the most efficient way it must embrace new technology and digital working. The 2016 NBS National BIM report shows that 86% of respondents expected to use BIM in projects this year. This highlights that different sectors across the industry have embraced BIM and are using it as an alternative to traditional design methods. However, the majority of BIM-ready companies are large players with small to medium-sized companies being left behind. In order to address this, we have worked with the CITB through its Flexible Funding – Innovation pilots to carry out a 12-month study assessing the BIM readiness of small and medium builders. As part of this project we have designed and launched a Stewart Milne Timber Systems BIM library, the first timber frame BIM library in the UK.

1 This features 112 of our products, including walls, floors and roof products and is free to download from the BIM store. The use of the library will reduce lead-in time on a timber frame project by as much as a month, by removing the need for a threestage ‘back and forth’ design process between architects and the SMTS design team. Instead, accurate 3D models can be prepared immediately after downloading content from the BIM library. As part of the project, a survey was carried out of our housebuilding company’s supply chain to assess its BIM readiness. Only 2% of respondents were BIM-ready with

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

32% of companies actually aware of BIM. This has brought into sharp focus the work which needs to be done to ensure that companies have access to the necessary BIM content to develop BIM 3D models which they can use and gain benefits. Following the completion of phase one of this project, we are looking to develop a trial site within Stewart Milne Homes, to further refine, test and challenge our progression to digital working. This will allow us to continually improve and drive out further benefits, as our BIM maturity levels increase and our BIM library grows, to the benefits of our clients.

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As part of this project we have designed and launched a Stewart Milne Timber Systems BIM Library, the first timber frame BIM library in the UK.

There has been a focus on the use of BIM in government contracts, with the UK Government requirement to adopt BIM Level 2 on all its projects by last year. In parallel with this, private sector companies are also moving to BIM-enabled platforms, as it just makes good business sense to do so. Work will continue but it highlights the opportunities which could be missed by companies who are not up to date with the latest technology and embracing digitisation. The Real Benefits 3D BIM parametric digital working is the future technology and will ultimately replace 2D CAD line drawings. The library has been configured as simple drop down tabs, with a ‘five click’ search and select principle, supported with a simple user-guide on how to download and use the information. Once the 3D building model is complete, this can be sent to our design team whom can automatically create a 3D IFC file of the timber frame structure and export it back into the BIM model. Thereafter the 3D timber frame model can automatically create the timber frame manufacturing and onsite assembly drawings and material schedules. These can be fed direct to our automated production lines, using our existing CAD/CAM – human machine interface, production control system, which governs the automated manufacturing lines – ensuring a high quality product is delivered, efficiently and with little waste. A feature of

3 BIM is the ability to translate the 3D model into virtual reality, where clients can view the building before being built, including the timber frame construction products used. In the future, the library can be developed to 5D BIM format, including additional aspects such as cost, time and quality management. It’s encouraging to see the recognition from the industry of the benefits offered by innovations like BIM and digital working. Getting the whole supply chain ready to take advantage of it, not just the bigger companies with the resources to invest, will be key to delivering the benefits to the most important part of the construction sector – the end user.

For more information visit: http://timbersystems.stewartmilne.com Images: 01-05. SMTS are using BIM as an integral part of producing precision sustainable buildings.

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

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SUPER CLT STRUCTURE FOR FIFE

1 The new Kelty Community Centre in a former West Fife mining village with an adjoining primary school showcases the use of cross laminated timber (CLT). The new facility was developed as an integrated community solution that provides local office, library, learning kitchen and IT suite and sport facilities. The link connection to the school accommodates two classrooms and enables all accommodation to be fully accessible and shared under one roof. The aim was to create an attractive environment to support community Hub Facility within Kelty. The entrance hub has a direct adjacency to the streetscape, offering civic identity and a sense of place. The primary school is connected to the community centre through a secure link corridor, with access to many facilities not normally available to a primary school. CLT timber panels were used as the main structure for the Games Hall, utilising panels spanning 10 metres to the supporting glulam roof beams and highly insulated closed panel factory manufactured roof cassettes. At the time of construction, this project was the largest CLT structure in Scotland. Following completion of the main CLT structure this was clad with highly insulated closed timber panels, which combined with the roof cassettes

with great attention to junction details creating a highly insulated building envelope. The insulated envelope, provided a weathertight solution quickly that facilitated the early introduction of other trades. As client and contractor, Fife Council saw the use of offsite fabrication and in particular CLT as a key benefit to the overall project. For the construction team it would reduce the site programme to allow early integration of follow-on trades and eliminate many traditional â&#x20AC;&#x2DC;wet-tradesâ&#x20AC;&#x2122;. For the design team and end users, the quality of the end product could be guaranteed with the knowledge that the solution would create an appealing visual environment that would benefit school pupil attainment and community groups. The CLT subcontractor was selected through a tendering process based on their ability to work with the design team during the pre-construction period and form an integral part of the supply chain. This offered confirmation of how the main structure would be formed during the design period facilitating co-ordination of services at an early stage of the design. The

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costs for the CLT/timber kit elements of the project were developed early avoiding the need for abortive design works potentially required to ensure the project remains on budget and having been part of the design process the CLT/timber kit sub-contractor were already well advanced with their manufacturing drawing when the construction phase was given the go ahead, allowing site work to start almost immediately. The use of a highly engineered solution for the main structure ensured a high standard of finish through the project allowing early occupancy and minimal defects. With the increased energy efficiency proposed for the building the embodied carbon in the construction was a more significant element of the buildings overall carbon footprint. Therefore as the sub and superstructure represent the majority of the embodied carbon footprint, the selection of timber as the main structure and envelope has significantly reduced the buildings embodied carbon. The lighter structural loads and a greater load distribution of CLT on the foundations mean the need for materials with high embodied energy is significantly reduced (e.g. concrete). For Fife Council as client, operator and designers the selection of offsite has enabled successful delivery of a light, bright attractive environment to support the local community and this builds on the success of the original community centre that no longer met needs and aspirations. The use of CLT has created a warm and visually appealing aesthetic that is appropriate for a community centre and primary school, particularly where the CLT has been left exposed in the Games Hall. The use of offsite CLT fabrication as the main superstructure has meant the facility was delivered much quicker than a traditional build and met a very challenging programme. For more information visit: www.glulamsolutions.co.uk Images: 01. CLT was a sustainable and carbon-friendly structural solution for Fife Council. Courtesy Fife Council Property Services

CASE STUDY

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PITCH PERFECT PAVILION

1 The Boilerhouse project for Royal Holloway, University of London, employs imaginative use of timber to respond to the industrial context of the site’s history and provides a café, event and social space for the University. The primary structure of the new pavilion comprises a flitched timber and steel structural frame pavilion with stainless steel braced bays and a double curvature plywood roof. A glass facade expresses the architectural form of the timber super-structure and the sculptural-curving plywood roof form and reveals the warmth of the original red brick courtyard boundary wall, enhancing the heritage context of the site. Offsite methods of construction were used with factory manufacture of components which had been preassembled and tested offsite, then delivered ready for immediate erection. This helped to minimise disruption to the university campus during construction. The project was delivered to a fast-paced six months’ timeline from planning to completion, with a successful two month Listed Building Consent planning process including all liaisons with Historic England. Variation of sizing of parametrised timber panels allowed the construction to achieve the curved aesthetic form. Although the ply soffit/ wood roof make-up appears to be curving along two different axis, BIM has been used to generate a mathematical formula

for each element to be built along a straight axis and faceting to the designed aesthetic. The soffit panels are exposed birch plywood, with appropriate finish treatment to interior and exterior. Individual roof cassettes were assembled offsite with CNC files taken directly from the 3D BIM model. The sawn timber roof deck provided the necessary flexibility to cover the double curved surface and was also used as part of the stability of the building structure, transferring loads back to bracing points. Birch plywood faced panels were chosen for their strength, beauty and ability to take on the complex curvature of the roof form. Perforations within the panels allowed the soffit to also act acoustically, reducing pressure on the budget for additional materials. BIM allowed accurate sheet cutting and perforation manufacturing, accommodating subtle dimensions of soffit faceting to a tight budget and fast paced programme with minimal material waste. Prototype sections of both superstructure and soffit bay allowed refinement and benchmarking to take place prior to manufacture of the majority of components, followed by sign-off and acceptance by the client and the design team that the finished article would be of an assured standard, minimising time-consuming snagging and remedial works onsite, and effective and efficient delivery by the offsite supply chain.

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3 The double curve roof plate was made in situ in the factory before being disassembled into transportable panels, meaning the complex shape could be re-assembled onsite without too much difficulty. The triangular panels were stored onsite for the fit-out-phase, to rigid coded locations for each correct element. The timber for the principal Douglas fir glulam frame was UK-grown and made into glulam in a factory in Devon. The reason for choosing UK grown timber was mainly down to finding the best quality available – proving that high-quality timber is grown locally. As a highly-engineered product, assembled in factory conditions, accurate cutting of the prefabricated timber sheets significantly reduced potential material waste. From feasibility stage, the project was designed to utilise offsite methods of construction to meet the client’s tight programme and budget. A pre-fabricated structure tested offsite and delivered ready for immediate erection meant that disturbance to the university was limited and campus life maintained. Timber was the obvious choice for the prefabricated structure with its sustainability credentials, strength, quality and beauty. For more information visit: www.cartwrightpickard.com Images: 01-03.The Boilerhouse mixes the best of timber structural technology and offsite thinking. Courtesy Cartwright Pickard

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Increase the Productivity of House Building by Utilising Innovative Modern Methods of Construction. The Governments ‘Fixing our Broken Housing Market’ report states: “The housebuilding industry is less productive than the wider economy, partly because it has been slow to modernise and make use of more efficient and faster ways of building.” Steve Hardy, JMD of offsite specialists SIDEY tells us that “offsite construction is absolutely the way forward in delivering cost effective, long term thermally efficient, and quick to deliver dwellings for future generations. “The Governments ‘Fixing our Broken Housing Market’ report also states: “By increasing innovation and making greater use of modern methods of construction we can change this. Industry reports suggest homes constructed offsite can be built up to 30% more quickly than traditional methods and with a potential 25% reduction in costs. They are high quality, reliable, more productive and can be highly energy efficient. They can require fewer people on site, helping to mitigate the skills shortage. Some firms are increasing their use of these methods, but we need to go further.” This report throws the spotlight on the Scottish housing crisis, we need to be innovative in our delivery and grab Modern Methods of Construction with both hands.

OFFSITE CONSTRUCTION IS THE SOLUTION

“There is a growing lobby of government agencies, procurement organisations, and individual housing associations all reviewing whether they should directly invest into, or partner with offsite manufacturing factories; they are recognising that the housing crisis which the country faces is being exacerbated by a basic failure in the construction sector – an inability to deliver on time. Offsite is well and truly proven as a construction option and it is the way forward for the housing sector wanting to build better quality homes; cost effectively, and most importantly sure to be delivered on time”.

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Steve Hardy also stated “The solution to some of these problems lies in the growth of offsite construction. Costs are now no more than when building through standard construction methods, but the two huge pluses are the delivery of better buildings by design, and delivery on time”.

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OFFSITE METHODS THE NEED FOR INNOVATION Dave Coldham, Specialised Products Divisional Manager of IKO Polymeric, explains the reasons behind moving towards offsite solutions in the roofing industry and illustrates some drivers for change.

1 Uncertainty in the national and global political situation has had an undeniable impact on the construction sector’s confidence. Article 50 has now been triggered and we are officially leaving the EU but the questions surrounding skills shortages remain a constant debate. Nearly 8% of the 2.5 million construction workers come from abroad, the majority being from the EU. Experts say the actual number is even higher. In anticipation of the problem getting worse before it can get any better, innovative construction products are being introduced to the market. IKO Polymeric’s offsite manufactured composite roofing panel Armourdek offers a solution that no other manufacturer in the market can currently match. Benefiting from a permanent and highly-skilled offsite workforce, Armourdek is manufactured in a controlled factory environment. It doesn’t require the level of onsite labour that a traditionally built-up roofing system needs. The traditional built-up roof system would require a deck/substrate to be installed, along with a VCL, insulation boards and waterproofing layer.

All of these components are individually installed and fixed onsite, which of course requires a trained workforce. Armourdek incorporates all key elements of a roof build-up together in one component. The structural supports are incorporated within the panel too – so for instance, purlins and joists are not required, avoiding another onsite installation. The lack of skilled construction workers and Government’s Construction 2025 Strategy left the contractors with so many difficulties to deal with. Not only did they have pressure from their clients to deliver faster projects but were also challenged to improve their thermal and acoustic performance. Identifying the need for a solution, we came up with the idea of Armourdek. With its long spanning capabilities, this composite roofing panel can reduce the installation times by 50% and offers high thermal and acoustic performance. According to a recent report, the UK needs to cut down its carbon emissions by 80% - a third of this is caused by heating poorly insulated buildings – to achieve the low levels of greenhouse gas emissions by 2050. Government wants to prioritise the energy efficiency as a national infrastructure by putting a ‘zerocarbon’ policy in place for buildings as of 2020. Armourdek’s high thermal performance ticks another box for the specifiers who want to meet the new parameters of the industry and work towards the future’s energy-efficient, sustainable buildings. Armourdek’s pre-fabricated panel provides improved quality control procedures within the factory environment, minimising the installation errors onsite. It also reduces the risk of accidents that might occur as a result of working at height

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and offers a safer manufacturing environment. Manufacturing in the factory also avoids the negative effect of poor weather conditions, especially in the winter months, leading to project delays. When the product is delivered to site, it is complete and ready to install without generating any waste. Unlike some traditional roof build-ups, Armourdek deliveries all come from a single-point source reducing the number of vehicles, which contributes further to CO2 reductions. An average construction site only achieves around 30% productivity, due to so much down time during the process. Offsite factory manufacturing can achieve around 80% productivity which cuts down the manufacturing costs, as well as providing shorter turnaround. With early project engagement it is also possible to reduce the material costs, as fewer support elements would be required in the building frame. Historically, innovation in the construction sector has not been rapid, but going forward the industry is pushing its borders with innovative products. Products such as ours add value to the construction process with fast-track installation, excellent thermal and acoustic performance, reduced material costs and CO2 emissions, improved site safety and ‘zero-waste’ to landfill. For more information visit: www.ikopolymeric.com Images: 01. Armourdek roofing system installation

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Armourdek ticks all the boxes in terms of the Governments Construction 2025 Strategy, providing:

50% faster delivery 50% reduced carbon 33% lower costs

www.ikopolymeric.com e: polymeric.sales.uk@iko.com

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CITB

OFFSITE: FASTER, SMARTER, MORE EFFICIENT The latest upswing of interest in offsite manufacture could change the construction industry fundamentally and provide a solution to the UK housing shortage, but as a new Construction Industry Training Board (CITB) report shows, only if the sector develops the right skills. The latest construction industry analysis to try and understand and predict the future impact of offsite construction has come from the Construction Industry Training Board (CITB) in its report ‘Faster, Smarter, More Efficient: Building Skills for Offsite Construction’ – the report’s aim being: “To provide a robust evidence base of the likely nature of industry demand for skills, training and qualifications in offsite construction and onsite assembly over the next five years.” It is worth remembering that presently offsite construction accounts for only 10% of construction industry output. The report – which closely follows the recommendations set out in Mark Farmer’s 2016 ‘Farmer review of the UK construction labour model: modernise or die’ – reveals that nearly 50% of construction industry clients expect the use of offsite construction to increase over the next five years. The CITB investigations and interviews reveal that 42% of construction industry employers with over 100 staff expect to use offsite methods in five years’ time. Speaking about the CITB report, Mark Farmer said: “This report comes at a crucial time for the construction industry. The urgency for modernisation has never been greater, set against an insidious backdrop of an ageing workforce and increasing concerns about the impact of Brexit. Any strategic shift towards premanufacturing and offsite construction creates an immediate requirement to define our future skills needs through collaboration between industry, educators, training providers and government.

“This is crucial to ensuring we can transition to a higher productivity, digitally enabled industry which inherently attracts more of the young talent we so desperately need. It should also set out clear opportunities for the existing construction workforce and indeed workers from other industries to reskill through a new family of career pathways. I welcome this report from the CITB and hope it adds to the current growing momentum for industry change.” The report outlines six key skills areas related to offsite construction: • • • • • •

Digital design Estimating/commercial Offsite manufacturing Logistics Site management and integration Onsite placement and assembly

Increasingly, workers will need the skills to move between offsite and onsite environments and so the training for these six areas must evolve to meet the changing demand. When exploring the use of offsite-specific construction materials and products and asked the question: ‘Of the types of offsite construction materials and products used on your work, do you expect the level of use over the next 5 years to increase, decrease or stay the same’ – an amazing 100% of respondents asked said they expected the use of precast concrete panels to increase with 91% anticipating the use of precast concrete frame to rise. There is also desire for a more developed product in housing, using the likes of closed panels and pods with manufacturers expected to produce more closed panels systems and hybrid (integration of panels and bathroom/kitchen pods) as a result.

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“There is massive potential for offsite construction,” says Steve Radley, Director of Policy at CITB. “The Government recently announced an additional £1.4bn of funding for affordable homes, with an increase in offsite construction set as an objective, representing a clear opportunity for growth in this area. That’s why CITB has set out a clear strategy within this report to show how we’re going to work closely with industry over the next five years to push the offsite agenda forward. The greatest potential currently lies within the housing and commercial sectors, where mass customisation can create the buildings we need more quickly and to higher standards. There are also opportunities to bring the benefits of offsite to largescale infrastructure projects – some high profile examples include HS2 and Hinkley Point, which are already using offsite techniques.” Currently, significant barriers exist which prevent the delivery of training and skills to meet the needs of crucial areas. These include existing training not including enough offsite content with a lack of awareness and suitability of available training and qualifications – companies are delivering their own ‘in-house’ training, which leads to non-standard approaches. And even though offsite construction is understood at some levels, there is a huge shortage of qualified training providers and assessors to demonstrate how offsite manufacture fits in with existing building methods and habits.

CITB “Successful offsite management hinges on the effective integration of both onsite and offsite functions,” adds Steve Radley. “This requires a comprehensive understanding of both aspects. Our next steps will focus on the delivery of the required employer training, knowledge and soft skills, tailored specifically to the six key areas identified in the report. This will also include a review of the available training and qualifications to make sure we address any gaps and issues. We will also work with other stakeholders – such as in design and manufacturing – to apply existing training in a construction context. We will step up our promotion of the career opportunities offsite can offer, emphasising digital skills, to attract a wider pool of people into these key roles.” The primary research contained in the CITB report points to a strong demand for training in offsite construction knowledge and these ‘softer’ skills, to bring about behavioural and cultural

change necessary to enable upskilling of those coming from a ‘traditional’ construction background. This includes differences in knowledge needs, largely linked to the types of materials used in different projects, different markets (e.g. housing) and between Scotland and the rest of the UK. Timber frame is a mature market in Scotland and as such the need for training in other materials including concrete and steel may be a lower priority compared with the rest of the UK. As one UK housebuilder is quoted as saying: “It’s about changing deep-rooted mindsets …it’s about re-engineering thoughts and attitudes.” In a full and comprehensive report, the CITB also makes it clear it is vital for them to have a clear understanding of the extent of current and future demand for offsite construction skills and training, and of the actions that need to be taken to respond appropriately and in a timely fashion to industry needs.

Importantly – and Mark Farmer also points this out neatly in his own review – with offsite construction it is important to note the use of the term ‘potential’, it is only possible to fully capitalise on the benefits that offsite offers if processes, skills and project management are all fit for purpose. When projects do not go to plan, or planning is not poor, problems can be very costly to fix, and can help perpetuate negative perceptions about offsite. The offsite bar is there to be raised. It is now up to all those playing a significant role in the offsite market to make sure that standards don’t slip and ruin the opportunity of a generation to embed excellence into offsite everywhere. For more information on the CITB visit: www.citb.co.uk To download a copy of the report ‘Faster, Smarter, More Efficient: Building Skills for Offsite Construction’ visit: http://bit.ly/2pxvXlc

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JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

MODULAR MATTERS

MB1 LIVE

Public sector procurement specialist LHC has launched a new UK modular buildings framework. The MB1 has a combined value in excess of £1 billion and will help provide a range of new facilities. Seven companies have secured the opportunity to provide goods and services through the newly launched MB1. This framework working across England, Wales and Scotland over a four year period will be available in Scotland under the Scottish Procurement Alliance (SPA) and in Wales under the new Welsh Procurement Alliance (WPA). The framework is available to all public sector organisations throughout mainland UK and offers easy access to offsite manufactured, modular building systems for use in non-residential buildings. This includes education, healthcare and emergency services buildings, as well as office buildings, community halls and sports facilities. The MB1 framework also provides users with the ability to purchase units or have them on short and long-term hire. This is the second offsite framework in LHC’s product portfolio that not only offers aesthetically pleasing modular buildings at a very high build quality, but also provides sustainable buildings

for a variety of project types and styles and multi-storey configurations. Suppliers appointed to the framework offer compliance with the latest British and European Standards, along with improved acoustic performance for separating walls and floors, reduced thermal bridging and improved air tightness through fabric energy efficiency. LHC Appointed Companies are: • • • • • • •

Extraspace Solutions (UK) Module-AR MTX Contracts The McAvoy Group Portakabin Western Building Systems Wernick Buildings

The MB1 framework is available through three workstreams: one for specialist contractors with smaller project values, one for permanent modular buildings of any type and one for temporary and relocatable buildings for purchase or rent. “We are delighted to have launched this framework, which is the second offsite framework in LHC’s portfolio,”

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said Tony Woods, LHC Technical Manager. “The suppliers appointed demonstrate the quality of the services offered and also show how we are now appealing to clients with a range of project needs. This framework offers our clients improved predictability of costs due to controlled factory production costs, as well as a faster speed of build, as much of the work is completed in the factory. The value engineering used by our suppliers can also help save costs, including reduced preliminary and carpentry costs. LHC offers an agile approach to developing new frameworks in response to a variety of client requirements and our new modular buildings framework demonstrates this.” For more information visit: www.lhc.gov.uk/Frameworks/MB1

WHY MODULAR MAKES A DIFFERENCE Within the healthcare sector modular construction is delivering a host of new, much needed buildings - one of these is the new Daisy Hill Hospital. The new building from McAvoy features two operating theatre suites which include scrub up, preparation, utility and anaesthetic rooms, stage one and two recovery wards with discharge lounges and ancillary spaces, an eightbed day surgery unit and an endoscopy decontamination suite. The McAvoy team worked closely with Trust and Health Estates teams to manage the substantial risks and deliver a technically complex and high profile project. The extension to Daisy Hill Hospital was constructed on a steel gantry 15 metres from the ground and was connected to the existing theatre level of the main hospital at first floor level. The 800sq m steel framed construction was engineered to accommodate a 230sq m plant room on the roof of the building. The design and specification of Daisy Hill Hospital is in compliance with all current Health Technical Memorandums (HTM’s) and Health Building Notes (HBN’S) and provides the latest technology enabling medical professionals to deliver modern, effective healthcare. For more information visit: www.mcavoygroup.com

Images: 01. Brampton Manor Academy Courtesy of Wernick Buildings 02. Cambourne Village College Courtesy of Portakabin 03. Daisy Hill Hospital Courtesy of McAvoy

EXPLORE OFFSITE AT ECOBUILD

ECOBUILD: THE NEW APPROACH

Following its acquisition of ecobuild, Futurebuild Events Ltd is making big changes to the 2018 event to ensure a fresh and relevant format. This includes the development of the Offsite Construction District. Managing Director of Futurebuild, Martin Hurn reveals more. We are determined that ecobuild under Futurebuild’s ownership will be very different. For us, the future of ecobuild is all about ensuring that it is truly designed by and for the industry. We see our role as organisers to facilitate, rather than dictate, the agenda. In practice this means bringing together and engaging with the most innovative, exciting and inspiring brands, companies and speakers to ensure the best possible experience.

Our goal is to bring the future of the built environment to life. Featuring the latest technology, the freshest thinking and the most innovative materials, presented through thought-provoking, valuable content and knowledge sharing. In short, we want to ensure every visitor has gained genuine insights and built new relationships to keep them at the forefront of the built environment.

Last year, Explore Offsite was one of the most popular elements of ecobuild, with many of the most innovative and forward-thinking brands coming from around the globe representing the sector including well-known brands such as Wernick, Portakabin and Hadley. The area was also supported by leading offsite experts Cogent Consulting and key industry media – Offsite Magazine and Offsite Hub.

Ecobuild and Offsite Offsite represents the future direction of construction technology and will be a key element in our vision for ecobuild 2018. The opportunities are immense. Offsite construction is rapidly expanding, with a 35% increase per annum. Yet at the same time, an estimated 90% of the construction market is still to adopt offsite technology. There are so many opportunities offsite construction offers to both private and public sectors – a bespoke solution to the housing shortage, shorter build times, less waste and lower costs for buyers. The challenge is educating and inspiring the wider built environment about this potential – which is why we are working with leaders in the sector to make offsite at ecobuild bigger and better than ever before.

Scaling up this success, ecobuild 2018 will see the offsite focus return and grow, developing into an Offsite Construction District. In partnership with Explore Offsite and Cogent Consulting, it will include more exhibitors and have masterclasses showcasing the latest offsite innovations. New partners include key associations such as the Structural Timber Association (STA), the Modular and Portable Building Association (MPBA) and British Precast.

The district will focus on key industry innovations and provide a comprehensive and balanced perspective on this rapidly emerging sector from a host of UK and international suppliers. During the three day event, a number of offsite solutions will be showcased including: framing systems in concrete, timber

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

and steel, modular and volumetric systems, bathroom and kitchen pods, offsite roofing technology, preengineered building services and a range of prefabricated building components. There will also be daily CPD-accredited masterclasses where you will be invited to learn about the latest in offsite technology and lean manufacturing systems – these masterclasses will offer an independent perspective on the offsite construction sector as a whole. What we already have lined up is exciting. But for ecobuild 2018, we want to challenge the offsite sector to move it even more to the forefront of construction thinking – we want to hear from you. We want you to help us shape the event and ensure we are showcasing the very latest thinking and innovations in the sector. Get involved and share your thoughts on how you want the show to look, contact the ecobuild team on social media using the hashtag #ecobuild2018 or email: martin.hurn@ecobuild.co.uk

Images: 01. Explore Offsite at Ecobuild 2017 was one of the most popular areas and will be revamped and bigger for 2018 as the Offsite Construction District

Join us at the Build Show 2017 10 -12 Oct 2017 NEC Birmingham part of

(part of Construction Week)

10-12 October 2017 at NEC Birmingham

2017

The MPBA are the

representative body of the volumetric and portable building industry

www.mpba.biz

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RECRUITMENT & BREXIT

PREPARING FOR UNCERTAINTY That is not to say a move to offsite construction will solve the skills shortage or save the construction industry – far from it. Even with EU workers, the offsite industry itself is suffering from a massive skills gap which only increases year on year. A lack of EU workers and the current lack of training in the UK will only increase this and have a detrimental effect on UK businesses. Brexit has the potential to destroy the UK construction industry, without EU workers and serious investment in skills, catastrophic damage will be done.

Could Brexit spell the end for the UK Construction Industry? Jim Roach, Managing Director of specialist recruiter ARV Solutions, highlights a range of issues surrounding recruitment and the future of a skilled workforce. As I sit down to write this article Theresa May has just signed a letter that will trigger Brexit. Formally beginning the UK’s departure from the European Union, triggering a period of uncertainty for thousands of EU workers and putting the future of the construction industry into jeopardy. The implications will undoubtedly have a negative impact on the construction companies who have come to rely on European labour and the impact will be equally as negative with regards to the current housing shortage. It has also been reported that the number of EU workers coming to the UK has already fallen post Brexit, further contributing to the shortage of a skilled workforce. The UK government has so far refused to guarantee the status of EU nationals before the EU exit, with negotiations

not scheduled to begin until later this year. It has been estimated the UK is facing a workforce shortfall of 3.1 million people by 2050. Not just due to the EU exit but also due to the skills shortage and an ageing workforce. It’s beyond time to act. The uncertainty Brexit brings, is partly pushing forward a resurgence in offsite construction. Traditional construction companies have stated they are looking into new developments using offsite construction. They are aware there is a need to futureproof their businesses so are looking to offsite. Offsite commands a fraction of the labour of traditional construction. There are the sustainability benefits too, however importing costs are high. Investment in home-manufactured solutions has a huge advantage that should not be overlooked.

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

There is a serious lack of training, apprenticeships and education surrounding offsite skills. One notable area of offsite construction that will be greatly affected is the ‘design office’. Already the skills shortage is significant in this area and there is much competition for candidates. Over 30% of our placements within the design sector in the last two years have been for non-UK nationals. The fact of the matter is there just aren’t enough designers within construction. At the risk of repeating myself, the reasons for this are the usual, lack of education, training and low salaries. It just isn’t as appealing as other industries. Construction designers unjustifiably receive lower salaries than other industries. So what happens if the supply stops? It’s a massive threat to our industry. We need to keep new designers coming. We must be proactive. Train more, pay more – make the industry more attractive to talent. Don’t assume someone else will save the industry, don’t assume talent will just fall in your lap and don’t assume that people will automatically want to work for you. They won’t. Is it all doom and gloom? Are there benefits to less EU workers? Perhaps for sought after talent. In an already candidate-driven market this could be beneficial to those left behind in terms of a salary hike for those with skills that will be even further sought after – brilliant news for some people. It could also force the lack of training and education within the offsite construction industry to be addressed, forcing businesses to develop a new way of working.

RECRUITMENT & BREXIT Offsite Jobs Online Isn’t it better to be proactive rather than reactive? What can you do? Invest in apprentices, this allows you to grow talent in-line with your business goals. Invest in training (TRADA or the Offsite Management School both offer free training), consider cross-training and candidates with transferrable skills. Don’t overlook trainees – grow your own talent and invest not only in their future but the future of your company. We need to keep fresh blood coming through the industry otherwise how will it grow? Campaign for local colleges to create relevant courses – could you collaborate with them? You could consider homeworkers and offer flexible working: this will open up a whole other pool of skilled candidates you could otherwise miss. Adapt and think outside the box. Don’t rule out a skilled workforce because of their working preferences or experience in other areas.

It’s a candidate’s market. They have the pick of jobs so why would they work for you? Don’t lose out to the competition – improve your salaries, your working environment, benefits package and make sure you have access to the very best candidates out there. Whatever the fallout from Brexit it is imperative that any new immigration system enables businesses large and small to retain and attract the workforce it needs. Whether that is nurturing homegrown talent or workers from outside the UK. Be proactive not reactive. Now is the time to invest in your talent and futureproof your business. For more information visit: www.arvsolutions.co.uk

If you are looking for a job within the offsite sector, why not visit the jobs board within the Offsite Hub, in collaboration with ARV Solutions. As the UK’s leading online recruiter in the offsite sector the Offsite Hub has an enviable position for recruitment solutions across modular building, pods, timber frame and roof truss, timber engineering, timber supply, curtain walling, cladding, SIPS and light steel frame technology manufacturers. For more information visit: www.offsitehub.co.uk/jobs

www.arvsolutions.co.uk info@arvsolutions.co.uk

Adding Real Value in Recruitment Specialists in offsite manufacturing, construction and supply chain ARV Solutions are the UK’s leading recruitment consultancy for the offsite construction sector and it’s supply chain. Our valueable relationships with our clients means we have access to unadvertised job opportunities. Each member of our team is a expert in their field and they are dedicated to matching candidates from trainee through to management level.

Our team’s specialist knowledge of your industry means they are best placed to offer you specific advice and support within this niche sector. From your job search to writing your CV. Call for impartial and confidential advice on your career: 0117 959 2008 or register your CV at arvsolutions.co.uk/register.

JULY 2017 | WWW.OFFSITEMAGAZINE.CO.UK

DATES FOR YOUR DIARY If you are interested in learning more about offsite construction and the associated manufacturing processes then choose from some of the following offsite events: DATE

EVENT

VENUE

WEBSITE

11 July

Explore Offsite Education

London

www.exploreoffsite.co.uk

The government has confirmed that an investment of c. £2 billion is to be allocated to rebuild or refurbish 277 schools across England. This integrated conference and exhibition event creates a platform for construction clients, architects, engineers and contractors to come together and discuss the latest offsite solutions in the education sector. 13 September

STA Factory Tour: Stewart Milne Timber Systems

www.structuraltimber.co.uk

Whitney

This factory tours takes place in the Stewart Milne Timber Systems facility and covers the process of timber frame production and construction from the material store through to the several mechanical cutting, nailing and finishing procedures to the finished product and delivery to the yard where they are stacked. 20 September

Explore Offsite Healthcare

www.exploreoffsite.co.uk

NEC, Birmingham

This event will present case studies of projects that have used offsite technology to create a new healthcare facility, upgrade or extension in a seamless way, ontime and on-budget working in a sensitive, inclusive and collaborative fashion. Speakers will discuss how they have met the healthcare provider and/or the NHS Trust’s expectations in providing a sustainable, energy efficient and cost-effective contemporary building. 21 September

EOS Facades CPD Factory Tour

www.eos-facades.co.uk

County Durham

The tour will include a demonstration by the estimating team of how the EOS ‘lump sum’ quote is generated, demonstration of EOS’ design software, followed by a tour of the factory demonstrating the new Howick FRAMA machine plus quality control, labelling, floor coding and traceability processes rounding off with EOS / Siniat external through wall system types and samples of the finished EOS product. 28 September

The Solution to the Housing Crisis: Offsite Structural Timber

www.structuraltimber.co.uk

Bristol

A host of speakers representing Timber Frame, SIPS and CLT will present the facts about structural timber, dispelling the myths, offering technical expertise and demonstrating the capabilities through a range of high calibre case studies followed by general association updates during the afternoon session. 10 October

2017 Structural Timber Awards

www.structuraltimberawards.co.uk

Birmingham

More than 500 leaders and innovators from across the construction sector will gather at the National Conference Centre, Birmingham for the Structural Timber Awards. The prestigious awarad ceremony will reward outstanding projects, innovative products and dynamic people promoting excellence in structural timber across the UK. 10-12 October

Timber Expo

www.ukconstructionweek.com

NEC, Birmingham

Part of UK Construction Week, Timber Expo covers a breadth of timber applications from timber frame through to sawmills, glulam to timber cladding. It is three days brimming with the latest products, innovations and developments across the timber sector - not just from the UK but from an increasingly exciting and diverse international market. 05 December

Explore Offsite Infrastructure

www.exploreoffsite.co.uk

Birmingham

Explore Offsite will see approximately 250 delegates and an exhibition of up to 30 companies, all from a range sectors that incorporate offsite construction in their infrastructure construction practice, covering rail, roads, airports and utilities.

CONNECTING THE UK OFFSITE INDUSTRY Online information centre offering industry news, project profiles, technical downloads and learning resources tailored to the offsite sector.

WWW.OFFSITEHUB.CO.UK 82

WWW.OFFSITEMAGAZINE.CO.UK | JULY 2017

BUILD BETTER. BUILD WITH SIG OFFSITE. SIG Offsite is designed to help todays construction industry overcome their most pressing issues. The range not only includes the complete fabrication of a house, multiple roofing and flooring solutions or modular pods, but they can also be fully fitted with insulation, electrics, plumbing, heating and external and internal finishes. Our solutions can be installed while your team carries on with other project demands without disruption and are designed to work alongside the traditional methods used in construction. At SIG Offsite we believe in working smarter not harder, which is why our services can be easily integrated into your current business model and put you in front of your competitors. We have years of experience operating across a broad spectrum of sectors including residential, commercial, education, health care, retail and aviation to name a few. So for your next project, build better. Choose SIG Offsite.

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www.innovaresystems.co.uk EDUCATION

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PRS

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STUDENT ACCOMMODATION

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RESIDENTIAL

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HEALTHCARE