Building News is an information portal for all professional building specifiers. Here you can find all of the latest construction news from around the UK and the rest of the world.

Pushing the envelope on building envelope construction

From architects to specifiers, installer to contractors, every player in the build chain must do their part in creating thermally efficient buildings, and that starts with the building envelope’s construction, explains Andy Stolworthy, Director of Product and Market Development.

 

With environmental legislation for building design and construction being updated across the globe, a new wave of architecture is being introduced. Architects and specifiers must find ways they can speed up building timelines, reduce energy usage and enhance a building’s lifespan when designing commercial and residential buildings.

The UK is making substantive improvements to its energy codes in order to reduce energy usage and wastage, seeing the construction industry shift towards bioclimatic architecture. Thermally efficient buildings using a well designed and installed envelope are crucial to this movement.

The building envelope is a protective boundary between the interior and exterior of a building that ‘wraps’ around the walls, floor, roof, windows and doors. This envelope shields the exterior of the building from natural elements, whilst facilitating climate control and protecting the indoor environment

Solutions that envelope energy efficiency

When a building envelope isn’t installed properly or is poorly specified, it will contribute to a substantial amount of energy loss, and one area that should not be neglected is the roof. More than 30% of heat is lost through the roof, and flat roofs particularly are prone to energy loss when a poor design is chosen.

There are two types of flat roof, warm and cold, the difference is the positioning of the insulation layer. In a warm roof the insulation is placed on top of the roof structure and choosing the right fastening solution will minimise the thermal bridging. This bridging is a funnel of unobstructed heat flow, which renders the surrounding layers of thermal insulation useless and ultimately can damage the building’s structure.

To prevent this, it is imperative the correct fastening solutions are used that work with the roofing system. Flat roofing solutions such as the Isotak thermally broken sleeve and fastener from SFS will ensure that the cladding is properly secured, therefore avoiding thermal bridges and decreasing energy loss.

The two-part fastener sits inside a polypropylene or polymide sleeve which penetrates below the surface of the insulation, providing a barrier between the fastener head and the external atmospheric conditions. This improves the whole roof’s thermal efficiency and reduces heat transfer through the building envelope.

The materials of the fixtures and fittings is another overlooked factor that contributes to excessive heat loss. Stainless-steel conducts heat at a slower pace than carbon steel which not only improves the thermal efficiency of the envelope but allows for improved corrosion-resistance, thereby maintaining the integrity of the installation and performance for longer. Installers should only use system approved fasteners and consult with manufacturers to identify the right fastener for the right situation.

Faster fixings that envelope efficiency

The building envelope is made up of a variety of different parts that make up a system – using the correct parts throughout will ensure a smooth building process. When the incorrect components are used, efficiency can go down as the wrong components can lead to unforeseen complications.

In the instance of a rainscreen subframe system, the manufacturer will typically just design solutions to meet mechanical and thermal needs. SFS’s NVELOPE system on the other hand will design everything down to the frame fastener to ensure the façade performs. Here is a perfect example where the right fasteners and fixings are paired with the right brackets and subframe systems and both construction and energy efficiencies increase.

Newer generations of fasteners, fixtures and brackets are being developed to aid a quick and easy installation too. For example, the SXC5 fastener is a self-drilling composite fastener that has been re-engineered to have an optimised tip and thread geometry, allowing installers to drive the fixing into the material they are fixing quicker.

As suppliers and installers enter this new wave of bioclimatic architecture, they must work together to ensure a successful construction of the building envelope. From training to on-site technical assistance and specifying the right components, all parties can secure the future of the building, speed up timelines and enhance its thermal performance.

www.sfsintec.co.uk

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Simplifying airtightness in modular & offsite construction

The A. Proctor Group has, for over 50 years, been serving the construction industry with an extensive portfolio of technically advanced thermal insulation, specialist membranes and vapour control layers, providing an extensive range of superior high-performance products suitable for modular and off-site construction.

 

The basis of best practice in modular construction comes from an understanding of the relevant building regulations and a holistic approach to the building design. In doing so we consider six core aspects in the process related to the balance of Heat Air Moisture Management (HAMM):

  • Building
  • Weather
  • Occupants
  • Heat
  • Air
  • Moisture

Building

The first area to consider is the type of building fabric involved. Concrete, steel and timber-based buildings all respond differently to moisture and contain different amounts of construction moisture which must be allowed to dry out. For example, buildings with a lot of in-situ concrete can take several years to fully dry out, this excess moisture load must be accounted for at the design stage.

Weather

Construction moisture can also come from the weather, and this must also be taken into account along with the weather conditions the building will be subjected to once completed. Being weather tight earlier in the construction process and generally being composed of drier materials, offsite construction has an important hygrothermal advantage.

 

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Occupants

By reducing the initial moisture loading on the building fabric, the design can be more precisely tailored to manage moisture associated with the occupants of the building and the uses the building will be put to, leading in turn to a more efficient fabric envelope and building system.

The influences of these three aspects can then be assessed in terms of the heat, air and moisture movement within the building. This takes into account the heating of the building, as well as the air leakage effects and response of the building fabric to the absorption and desorption of moisture. Factors such as the position and performance of the fabric insulation can also be considered.

To ensure our design adequately manages these complex interactions, we undertake a hygrothermal analysis of the building fabric using software called WUFI. This breaks the building elements into individual layers and calculates the temperatures, moisture flow and degree of water storage at any point in the building fabric. This detailed analysis allows us to consider solutions that may mean that the internal vapour control layer can be removed altogether without creating a condensation risk.

This is made possible by the use of an external vapour permeable air barrier membrane. The Wraptite® membrane self adheres to the external face of the sheathing and provides a robust airtight layer without compromising moisture movement through the wall assembly.

By removing the vapour control in favour of an external air leakage solution we remove the associated material and installation costs, and more importantly, we remove the need to seal all the service penetrations, meaning we have a more reliable air barrier and can reduce the air leakage rates applied at the design stage.

In modular systems, incorporating an external air barrier is simple and brings several benefits over traditional mechanically fixed membranes.

Wraptite membrane can be applied to the panels in any orientation, and being self-adhered requires no mechanical fixings. This adhesion reduces the potential for membrane damage both during the module assembly process and while in transit to the site.

The panels are then assembled and the joints taped using Wraptite Tape, ensuring no adhesion issues or tape compatibility problems, and the panel assembly is now resistant to air leakage. The wall, roof and floor panels can then be assembled into modules, and Wraptite split-liner tape used to complete the airtight seal between adjacent assemblies. The completed modules can then be transported to site with full protection from the elements.

www.proctorgroup.com

 

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The Complexity of Facades & the Risks Involved

In the last 10-15 years the building industry has gone through a multitude of changes which have impacted the role of facades and its growth in the construction industry.

 

Some of these influences are driven by:

  • Advances in manufacturing and material technology
  • Pressure to reduce project duration by using different construction methods
  • Environmental concerns
  • Aesthetics

No longer consisting of simple building elements, modern facades utilise new materials in increasingly complex systems and these are being assembled in untested combinations with other modern methods of construction (MMC) as well as traditional wall types. Untested unique and bespoke building interface arrangements have an increased risk of one or more of their performance parameters failing.

Modern Methods of Construction: Risks

  • More components
  • More interfaces
  • Less historic data / testing / familiarity
  • More complexity of design and geometry

Unravelling the complexities of modern facades and ensuring that the facade is considered holistically rather than elementally has become a specialism, and facade consultants are now often required on many projects. The role of the Facade Consultant is to ensure that both the aesthetic and performance requirements of the façade are met during the design and installation stages. It is important that a facade consultant with the appropriate level of expertise and diversity of experience for the project is selected.

 

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Finding a specialist contractor that can complete all elements of a facade is difficult, and in some cases impossible. As a consequence building envelopes are frequently divided up in to smaller packages. However, there comes a point when having too many specialist contractors becomes detrimental. Using a rainscreen wall as an example, we frequently see these packages being broken up into layers of, rainscreen and insulation, cement particle board, structural framing system (SFS), vapour control layer and plasterboard etc. with each layer being installed by different specialist contractors. This creates a multitude of conflicts and split design responsibilities within the ‘standard’ through wall element alone. Subsequently, these issues are multiplied several fold as soon as this construction hits an interface.

The short term savings generated by the splitting up of facade packages can quickly be eroded by extra management costs, site delays, additional costs from missed interface elements, etc. The risk of longer term (legacy) failures is rarely factored in when savings are tabled during the pre-construction phase; the ‘cost to remediate’ for legacy issues are many times more expensive than the original installation costs.

There are many reasons a facade can fail, all of which are avoidable, but to have any chance of mitigating failures the way that the specialist contractor packages are divided up needs to be carefully considered and it must be done giving due consideration to the capabilities of the specialist contractors that have been selected for tender.

Modern buildings are required to have reduced air permeability, greater u-values and better waterproofing. To do this they rely heavily on gaskets, sealants, tapes and membranes. At junctions and interfaces it is critically important that these elements are detailed and installed correctly, and that the different specialist contractors co-ordinate their works.

When properly managed and designed, modern methods of construction can offer economic, rapid and robust solutions that were unobtainable with traditional methods.

With such a high percentage of building failures being attributed to their facades during a building’s lifetime we have provided a few key tips to help avoid failure from the outset. Some may seem obvious but are also imperative when deciding on the different elements and installation of the facade.

  • Keep the number of specialist contractors to a minimum.
  • Ensure contracts provide clarity on design responsibilities and scope, with particular emphasis on interfaces.
  • When considering savings that may be offered/proposed at the pre-construction stage, question whether these savings have the potential to generate costs in the longer term (risk assessment).
  • Diarise regular design team meetings with all specialist facade contractors present.
  • Engage suitably experienced facade package managers and facade consultants.
  • Test unusual / untried interface details off site.
  • Agree robust QA procedures prior to starting on site.
  • Construct quality and installation reference benchmark areas on site that include examples of both the standard and non-standard details/arrangements.
  • Site test 5% of all interface waterproofing details.

www.premierguarantee.com

 

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Off-site Manufacturing – best way to accommodate student intake

Although provision of student accommodation, both in the private sector and university has increased over the last five years, demand for quality accommodation remains high.

 

When considering the provision of purpose built student accommodation timescales are frequently tight, with investors looking for a quick return on their investment.

Premier Modular, is an off-site manufacturer with over 60 years’ experience in the market, with a strong commitment to research and development, ensuring they bring the most innovative products to market, for both hire and sale.

Premier Modular has developed a highly efficient light gauge steel frame based factory engineered product.   Constructed by skilled assembly teams in Premier’s 22-acre site in East Yorkshire, the system is ideal for a full stand-alone build, whilst also suitable for rooftop extensions in tight inner city locations.

 

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The primary benefit of this product is a reduced programme; the product is manufactured on a flow line and therefore removes any impact the weather may have on delivery.   Rooms can be manufactured at a rate of 25 per week, with minimal onsite time. This speed of construction not only reduces labour rates and prelims but gives a much faster return on investment whether clients are selling or gaining a monthly rental income.

Speed of manufacture does not mean compromise in other areas though; modules are constructed to exacting levels in a quality controlled factory environment and with as much as 75% of the buildings manufactured off-site, the risk of accidents on site is greatly reduced. Impact on the local environment is also reduced, with reduced deliveries to site and most of the fit-out happening at Premier Modular’s factory.

Premier Modular, working as a supply chain partner to Sir Robert McAlpine completed a 5 storey 206 bedroom student accommodation block in Sept 2015. Located in Newcastle Upon Tyne city centre it consisted of a mixture of 54 studio flats, 105 en-suite bedrooms and 2 accessible en-suite rooms with associated living spaces, kitchens and study areas.

Premier was chosen as the preferred supplier due to speed of programme and the high quality finish that could be provided. The project was driven by an immovable programme requirement of the September student intake, Premier efficiently manufactured 300 modules fully fitted out and decorated in the factory – an excellent demonstration of the enormous time benefits realised by using the off-site system.

Significantly the foundations and demolition commenced on site whilst the modules were being manufactured – ensuring no time was wasted in the process.

Dan Allison, Divisional Director – Sales Division at Premier Modular said ‘Completing this project using off-site construction not only gave the investors a whole year of additional return, it was also a deciding factor in ‘The Foundry’ in Newcastle winning ‘Project of the Year Up to £10m’ at the Construction News Awards. The client is at the centre of everything we do and we take great pride in pushing the limits of modular design whilst balancing other key project drivers’.

In a market where an increased rate of build is required, building standards are increasing, sustainability is of upmost importance and high quality lifestyle choices are an expectation – Premier Modular’s off-site construction has the answer.

www.premiermodular.co.uk

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Engineered Framing & Modular Solutions For the Urban Built Environment

Our volumetric  and panel systems, constructed in light-gauge cold-formed steel, are designed for use on both residential and commercial projects including rooftop airspace developments.  Whether you are a contractor looking for a structural modular frame only or a property investor requiring a full turnkey service, we can tailor our services to your individual needs.

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Part of the Nexus family – we carry out all of the structural engineering design for Nexus projects, but also offer a standalone fully 3D design and detailing service for external clients. Work is carried out in a collaborative environment (BIM) and then details are prepared for direct insertion into the rolling mill (Howick, or similar).

A fully flexible solution for temporary and/or permanent accommodation, where speedy installation is paramount. Whether the need is for one person studios, or larger units for multiple occupancy, our designers will work to match that requirement. The single person pods can be stacked and joined to provide the required layout. We combine sustainable technology such as solar panels and battery storage into all our designs, with the aim of creating fully off-grid accommodation at a zero net carbon rating. Easily transported and erected on site, each pod arrives on site ready to “plug and play”. They can also be relocated with ease at a later date, if so required.

 

nexusmodular.co.uk      

 

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Expertise in the supply chain

Since launching their offsite window and door solution last year, Nationwide Windows Ltd, leading fenestration partner to the housing sector, reports that producing factory-fitted windows and doors is fast becoming part of their core product line. What is key to the success of their solution is the collaborative approach they have taken to delivery.

 

Adrian Pavey, Commercial Director at Nationwide comments: “New Build housing has been at the core of Nationwide since the very start, over 30 years ago, and through the years we’ve been at the forefront of many advancements.

While Offsite Construction isn’t a new concept world-wide, we saw that for the UK it provided a very feasible opportunity to help solve the housing provision crisis.

“Working closely with a small number of partners, each with their own knowledge of supply into the housing sector, we developed a new concept for windows and doors using offsite construction technologies, materials and service. We launched the concept at two exhibitions last year: The Build Show and The Offsite Construction Show. The idea was to use these exhibitions as a platform to not just showcase our solution to the right audience, but also talk to peers within the sector to learn more about this increasingly popular housebuilding technique.

 

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“Since then we have been working with our key partners to develop our offering. We’re now successfully delivering into three developments, with many more coming on stream.

“While the housing industry hasn’t fully embraced Offsite Construction, the balance is certainly tipping towards MMC. We’re delighted to be in a position to add expertise and experience to the supply chain as the market continues to emerge.”

For more information call 01788 224466 or visit the website.

www.nwd.co.uk

 

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Lindapter Hollo-Bolts provides solution to Seattle hotel

Modular buildings are gaining popularity as an affordable and sustainable solution. This design and delivery method has been adopted by Netherlands-based hotel operator citizenM, who have brought their steel-framed modular hotels to New York and Los Angeles.

 

Polcom Group, specialist off-site modular manufacturers, were appointed to build 228 modular units for the hotel. They identified that they would need to modify their normal production and assembly process to meet US building practices and standards.

Due to time constraints the traditional method of connecting units together on-site by drilling and bolting was not chosen, whilst hot welding risked damaging the critical waterproof membrane that protects each module.

Design Solution – Special steel structural shear plates were designed and added to the steel enclosures of the modules during production so that they could be connected to each other with Lindapter Hollo-Bolts during on-site assembly.

 

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Hollo-Bolt was specified for its high strength capacity and ability to be installed from one side of the Structural Hollow Section (SHS). Each module was wrapped in a protective air and water barrier, pressurised to keep windows in place and shipped on a private vessel from Poland to Seattle in the US.

Installation – Mortenson Construction were the appointed main contractor for the construction of this seven-storey, 264-room hotel. Each 18,144kg modular unit was lifted by crane and carefully stacked on top of each other.

Hexagonal head and countersunk Hollo-Bolts were then used to connect through the structural shear plates to the SHS of each module.

Installation was quick and easy. Each bolt was inserted into pre-drilled holes and tightened with a torque wrench to the recommended tightening torque to provide the necessary clamping force.

Result – Hollo-Bolts provided a weld free connection that was quick and easy to install without damaging the waterproof membranes.

This allowed the client to improve their modular construction method, which provided many advantages over traditional methods, including shorter constructions schedules, consistent quality control and reduced disruption on-site.

www.lindapter.com/Downloads/Market_Brochures

 

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Bringing Modular Benefits to Cleanrooms

Over recent years, the use of cleanrooms has spread from highly specialised fields, to an increasingly diverse range of sectors including vitamins and e-liquids.

 

A key challenge when creating these spaces is limiting energy usage particularly within HVAC systems which must be operated at a much higher rate than in a standard room. Pre-insulated ductwork systems offer a specialist solution, reducing air-leakage throughout the system and consequently cutting fan energy demand.

ISO Definitions

ISO 14644-1:20151 separates cleanrooms into 9 classes based on the size and number of particles within a cubic metre. This allows designers to quickly identify a specification appropriate for each rooms intended purpose.

These requirements are typically met by installing High-Efficiency Particulate Air (HEPA) or Ultra-low Particulate Air (ULPA) filters within HVAC systems and operating these systems at extremely high flow rates. CIBSE recommends a ventilation rate of 10-120 air changes per hour (ACH) for non-laminar-flow rooms and 500-600 ACH for laminar-flow rooms2 . This compares with just 2 or 3 ACH for a normal building.

At these rates, it is essential that ductwork is carefully designed and installed to minimise air-leakage. Whilst this is possible to achieve with conventional sheet metal ductwork, the added detailing will often add considerably to the installation programme length and cost. Pre-insulated ductwork systems offer a simpler solution.

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Advantages

Pre-insulated ductwork is typically formed from panels with an insulated core faced on both sides with aluminium foil. This eliminates the lagging stage and can significantly reduce weight when compared with galvanised metal ductwork, allowing long sections to be fabricated on or offsite and installed in a single operation.

The sealing methods and jointing systems featured on some pre-insulated ductwork can significantly cut air-leakage. In a comparative study of two identical buildings, the air-leakage from pre-insulated ductwork was shown to be 79% lower than for a sheet metal system lagged with glass mineral fibre. This means air-flow rates can be met with smaller, more efficient fans.

This enhanced airtightness is particularly beneficial for cleanrooms kept at positive pressurisation. Pre-insulated ductwork systems have been shown to support positive pressurisation of up to 1000 Pascal and their design reduces pressure fluctuations within the ductwork.

In addition, some pre-insulated systems use rigid insulation materials which are both highly thermally efficient and fibre-free. This reduces the risk of loose fibres entering the ductwork and can considerably lower energy demand in cleanrooms where air temperature must be carefully controlled as around 95% of the air is usually recirculated.

Case Study

Pre-insulated ductwork was recently used in the construction of an ISO 8 cleanroom for E-liquid manufacturer, Zeus Juice UK.

Cleanroom specialists — Monmouth Scientific Ltd — oversaw the design and construction of the rooms and specified the pre-insulated Kingspan KoolDuct System.

Monmouth Scientific operations director, David Court, discussed the installation: “We chose Kingspan KoolDuct for the air-distribution ductwork, which we designed to the pressure value of 500 Pa as. In addition to its high performance, we are able to produce a wide variety of shapes and sizes using our computer numerical control (CNC) router. This allowed us to construct complex shaped sections off-site to tight tolerances.”

Contamination Controlled

With technology developers continuing to seek smaller form factors and regulations to prevent contamination in food, supplements and other products tightening, the need for cleanroom spaces will continue to grow. Offsite construction methods offer clear benefits for these self-enclosed, high specification spaces and by utilising technologies such as pre-insulated ductwork it should be possible to create clean rooms which can be erected quickly and provide enhanced energy performance.

 

www.kingspanductwork.co.uk

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Concrete evidence

Kerkstoel 2000+ is one of the most innovative concrete companies in Europe.

It is part of the Kerkstoel Group and is based in Grobbendonk (Belgium).It specializes in the production of precast concrete walls and floors. Every precast element is made to measure in a highly automated factory.

Based on the architect’s design (general arrangements and cross-sections), structural calculations, formwork and installation plans, Kerkstoel 2000+ develops an installation plan, with all the necessary details, so that everything runs smoothly and according to plan on site.

The floors, or lattice slabs, are used as a structural and aesthetic underside of a concrete floor. Basically permanent formwork they are the ideal substrate for concrete floors and can be made in all shapes, up to 7 cm thick. Wide plates are equipped with bottom reinforcement and on the underside they have a very smooth surface. After placing the lattice slabs and propping the top reinforcement is installed. Finally, the slabs are poured with concrete to the desired floor thickness. The result: a solid concrete floor where the load is perfectly distributed.

 

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The reinforced twin walls of Kerkstoel consist of two shells of reinforced concrete that are connected to each other by lattice girders. All necessary built-in parts are provided in the walls during production (such as electrical boxes, power conduits, openings for windows and doors, wooden boxes, etc.).The wall elements are then assembled on site according to plan and then filled with concrete. The result is a solid construction as strong as a monolithic cast insitu concrete wall. These systems ensure high quality on site in a shorter construction time. The heavy skilled labour, such as steel-fixing and formwork, is limited to an absolute minimum.

Thanks to the hybrid character, namely the combination between prefab concrete and in situ concrete, with the necessary water-bars the walls can also be used for underground structures.

In 2018 Kerkstoel 2000+ invested in a brand new automated production hall. With this production hall, Kerkstoel wants to further specialize in the concrete wall sector. Concrete walls with integrated insulation, sandwich panels, walls with prints, etc. will now also be possible. Kerkstoel 2000+ has been active on the British market for more than 10 years, and has delivered walls and floor slabs to numerous contractors. Contact us and see what we can do for you!

www.kerkstoel.be/en

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Water services on tap

In recent times two major themes have emerged for developers to satisfy the urgent demand for homes and how best to make those homes “smarter” and therefore more environmentally friendly and saleable to discerning homebuyers.

The first point is to speed up the process of construction given the skill sets which are available (not to mention the British weather), the second to meet the environmental and technical demands of a more IT enlightened public.

Modular Homes:

Modular construction systems are probably the only way by which the UK can achieve the necessary build program to meet demand, quality, consistency and speed of construction, with all utilities being ready to literally “plug in”.

Given these requirements, traditional underground water control systems simply just do not fit the bill, either for accessibility or as a home for a meter.

The only realistic method of achieving this simple concept is to connect to externally mounted, pre-installed water service controls.

Our Groundbreaker water management system is the only such system available – designed to be installed at any time during the construction period, is fully (Water Regulations) approved and offers an accessible, safe and secure location for the water meter and controls to a specific property.

Because of its compact design, Groundbreaker can facilitate the early and secure connection of water services to a plot or unit, for both accessibility and water quality at a time to suit the developer’s program of events on site.

Groundbreaker was chosen by “Urban Splash” for its prestigious development at Irwell Riverside, Salford, as the most efficient method of achieving all the objectives, the scheme being “approved” by United Utilities who also saw the advantages of early connections to the water supplies.

By use of Groundbreaker, Urban Splash has been able to avoid the “clutter” of street furniture, allowing clean lines for the design of the project as will be seen from the images.

 

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Smarter water management:

Smart meters have been around for a while now, but every smart meter so far has had to be installed above ground as traditional underground water control boxes are apt to get waterlogged and are exceedingly poor in being able to transmit a signal to even a local pick up.

Besides facilitating water connections to meet rapid build programs, Groundbreaker also offers by far the best location for a water meter. Transmissions from a smart meter above ground – the location of the Groundbreaker unit – have proven to be at least 1 000x better than in the traditional locations.

We believe it is essential for the homeowner to manage his or her utilities and impact on the environment probably via a home hub with link to the ubiquitous “App” on a mobile phone or home computer.

Recently, Groundbreaker was chosen for the first pilot of a 5G transmitter associated with a smart water meter, no other product could have provided such a platform so successfully, leaving the way open for further “smart systems” to follow.

Groundbreaker is compliant with all relevant legislation as well as meeting the best practice recommendations of Water UK and the Home Builders Federation and can be used on more traditional building systems and refurbishment schemes.

For further information on Groundbreaker and associated products, please email sales@groundbreaker.co.uk , call on 01379 741993 or visit the website.

www.groundbreaker.co.uk

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