Latest innovations and products in the building fabric section of the construction industry.

Kemper System helps protect concrete heritage

Cold-applied liquid waterproofing specialist, Kemper System, has helped to preserve a grade II listed building thanks to its Stratex warm roof and Kemperol liquid roofing systems.

Because of the unusual design of St Thomas More Church in the Sheldon area of Birmingham, architects Wood Goldstraw Yorath worked in close consultation with Kemper System to enhance the waterproofing performance by addressing leaks and U/V damage to the existing substrate, whilst also improving drainage and reducing the risk of standing water on the roof.

The structure of the building with its many glass and concrete terraces, saw Kemper System’s Stratex tapered warm roof system being specified along with their solvent-free and odourless Kemperol 2K-PUR waterproofing membrane to refurbish the church’s failing asphalt roof.

The technical team at Kemper System also devised a series of drainage channels to address the volume of standing water on the roof, whereby excess water would be caught and drained off the building.

Contractors, Alliance Technical Services Ltd, a specialist conservation company, not only worked to recover the roof with Kemper’s Stratex warm roof system, but also installed new glazing to the central ribs and high level roof windows, fitted an external downpipe and drainage, and completed concrete repairs and concrete rib replacements.

For the recovering of the roofs with the Kemper designed system, operatives removed the existing chippings on the roof ready to clean and prime the asphalt substrate, and installed a hard top tapered Kempertherm PIR insulation board. This was adhered to each terrace section in such a way to create channels behind and either side of each piece of insulation.

As primarily structural engineers, Alliance Technical Services Ltd undertook thorough product and application training at Kemper System HQ in Warrington before installing the Kemperol 2K-PUR system, to familiarise themselves with the liquid waterproofing product application.

Derek Lowe, Managing Director at Alliance Technical Services Ltd, said: “This was a particularly interesting project for us as the church required remedial works to the concrete whilst also installing an alternative waterproofing solution to ensure the graded building remained watertight. The Kemperol 2K-PUR liquid applied waterproofing system was an ideal solution to work around the complicated structure of the building with its many terraces, outlets and joints. These formally weak areas were able to be fully waterproofed in one seamless, easy application.

“We undertook excellent training at Kemper’s headquarters to ensure we were able to apply the system effectively and efficiently. Thanks to the durability of the Kemperol 2K-PUR waterproofing system, the church’s heritage has been protected and can continue to be enjoyed by its many visitors.”

Technical manager at Kemper System, Ross Smith, added: “This interesting project presented design, specification and installation challenges which were easily solved thanks to versatile qualities of the Kemperol membrane.

“The wet-on-wet, cold applied liquid was the perfect solution to ensure a quick and easy installation, yet providing the reassurance of a sound, waterproof solution for many years to come. Its odourless, solvent-free qualities meant the refurbishment works created little disruption to local residents or those using the church.”

Added to Historic England’s ‘At Risk’ register in 2015, the Roman Catholic Church of St Thomas More was designed by renowned architect, Richard Gilbert Scott – who also designed the Guildhall’s West Wing and Art Gallery – with stained glass by John Chrestien.

For more information please visit www.kempersystem.co.uk.
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SFS intec’s Powder Coated Fasteners Deliver on Aesthetics and Performance in Prestigious Retail Project

Powder coated high performance fasteners from SFS intec have played a key role in enabling leading roofing and cladding contractor Roofdec to create a striking new building envelope for a major extension to the White Rose Shopping Centre in Leeds.

The prestigious £13.7m project completed by Morgan Sindall for client Land Securities expands the popular shopping centre with an additional 65,000 sq ft. This space incorporates an 11 screen Cineworld cinema with IMAX technology, numerous restaurants and an extension of both the existing Primark and Debenhams stores.

Meeting the colour consistency and long-term performance brief across the various elements of the contemporary façade, Roofdec turned to SFS intec for 40 variations of fasteners, many of which were powder coated in-house to match the different forms and colours of the rainscreen exterior. This included ensuring that fastener heads complemented the building’s unique curved facias which were formed of purpose-made anodised panels in various colours.

Jon Barnes Senior, Managing Director of Roofdec, says, “For all of our prestigious jobs, we choose SFS intec’s fasteners for their excellent quality, ease of installation and value for money.  SFS intec provide excellent technical support throughout the design and construction phases of a project and with their production facilities being located in Leeds with in-house powder-coating, the logistics to get the right coloured product on-site were a breeze.

“With their unbeatable warranty, we’re confident that we will have no teething problems on site and the sustainability of the building is secure for a longer warranty period.  Once the project is finished, we can move on to our next project with total confidence in our work.”

SFS intec powder-coats fasteners, available to meet any RAL colour and in bespoke finishes, at its UK HQ and production plant in Leeds. This ensures it can provide complete consistency in fastener design, manufacture and colour-matching for total peace of mind – all within industry-leading lead times.

The company’s sales and technical teams are available to advise on how best to colour-match fasteners with panels. Currently, SFS intec’s most popular requests for powder coated heads reflect the trends in contemporary architecture, and include Goosewing Grey, Poppy Red, Light Metallic Silver, Solvent Blue, Hamlet and Sargasso Blue.

David Osborne, National Sales Manager at SFS intec says: “With architects continuously pushing the boundaries of façade design, and OEMs leading the charge with constant innovation in panel design and construction, maintaining the visual appeal of the building envelope is vital, particularly for clients in the fiercely competitive retail market.

“Our powder coated fasteners, which provide a high-quality finish for our A2 (grade 304) or A4 (grade 316) stainless steel fasteners, is the ideal way to ensure a façade retains its integrity over a long service life, without suffering significant visual defects that will inevitably impact on the visual appeal of the structure.

Powder coating is an advanced alternative to using moulded nylon heads. Finely ground particles of pigment and resin are sprayed on to the metal fastener head using an electrostatic spray process, causing the charged particles to permanently bond to the metal surface. The powder is then heated and fused into a smooth coating in a curing oven at up to 200 °C, melting the powder onto the metal, to deliver excellent weather resistance and colour stability in even the most exposed locations.

Customers can access detailed information about all the fastening solutions available from SFS intec through its 2017 Roofing and Cladding Catalogue which is accessible via the new website www.sfsintec.co.uk. Customers can also benefit from UK-wide sales and technical teams, both dedicated to providing market-leading customer service, along with extensive resources and training facilities to ensure the best possible result in the finished building envelope.

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Brett Martin gives a new angle to £90 million former press and broadcast centre

The former press and broadcast centre in London’s Olympic Park has been transformed into the one of the biggest tech hubs in Europe, with Brett Martin Daylight Systems’ Marlon Clickfix RL glazing system glazed with Marlon Clickfix 1040 polycarbonate, providing a low pitch rooflight which maximises natural light and creates a bright, appealing and naturally-lit environment for a range of businesses.

From a design by Hawkins Brown, Here East is a major new 1.2 million sq ft development in Stratford that is set to transform creative and digital industries in London. Comprising three buildings – the former press and broadcast centres, and a 750-seat auditorium – the challenge for the main contractor was converting what were once windowless and cavernous warehouses into eye-catching, daylight-filled buildings with sustainability at their core. Central to the design was the specification of 34 Marlon Clickfix RL rooflights glazed in clear Marlon Clickfix 1040 polycarbonate to ensure the offices and shops below were bright, appealing and flooded with natural light.

Commenting on the specification, Steve Higgins of Brett Martin said “One of the challenges for the architect was finding a thermally-efficient rooflight solution which would work at a low 7° pitch. Marlon Clickfix RL provided the the most adaptable solution and ensured a fast and straightforward installation for roofing and cladding contractor, Lakesmere.”

A lightweight polycarbonate panel, Marlon Clickfix 1040 has integral interlocking connections that simply click into place forming glazed areas of unlimited size and shape. The 40mm structured polycarbonate glazing panel has 10 insulating walls to achieve a U-value of 0.99 W/m²K, for a high performing and thermally-efficient glazing solution. It has a choice of thermally broken aluminium glazing bar systems depending on the application. The Marlon Clickfix RL glazing bar system – used at Here East – has been designed for use in low pitch rooflights and canopies, whilst Marlon Clickfix VF has been specifically developed for vertical installations such as façades, partitioning, rain screens and northlights.

Marlon Clickfix 1040 provides high quality natural light, superior thermal insulation and UV protection. In addition to the impact resistance, resilience and structural strength that is inherent in all of Brett Martin’s high performance polycarbonate sheet products, it is also lightweight and easy to handle.

With this state-of-the-art digital tech quarter now complete, Brett Martin Daylight Systems will demonstrate once again that introducing natural light into spaces is central to achieving the required performance of highly sustainable buildings.

For more information please visit www.brettmartin.com.
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Handmade clay tiles create historic-style new build

Canterbury handmade clay plain tiles from leading roof systems manufacturer, Marley Eternit have been used to create an authentic roof for a new build historic-style cottage in the Denham Conservation area.

The self build project, in the picturesque old English village of Denham, had to adhere to strict planning guidelines for roof height and use of materials due to the number of listed buildings along the same road. The homeowner consulted independent roofing merchant Skyline Roofing Centres, who recommended the Canterbury clay tiles in Loxleigh to give a premium rustic aesthetic and complement the cottage’s Welsh oak timber frame.

The homeowner explains “Denham village dates back to the Doomsday Book and has 46 listed buildings, the majority of which are along Village Road where our new house has been built. These historic properties are largely vernacular with a mix of brick and timber frames and many of them have handmade clay tiles on the roof.

“We chose the Marley Eternit handmade tiles because they achieved the traditional, heritage look demanded by local planning and blended in well with the rafters and open eaves on the roof. They also complemented the copper gutters and downpipes, which needed to fit with planning requirements as well.

“We have been aspiring to build our own home for over five years, so we had a clear image of what we wanted it to look like and had even built a model of it. The handmade tiles have helped us to achieve our dream picturesque cottage, which sits perfectly in this idyllic village and is a welcome break from the busy city.”

Marley Eternit’s range of Canterbury tiles are handmade by skilled craftsmen, using locally sourced Etruria Marl, generally accepted to be the finest clay for strength and durability. The tiles are available in three colours; Chailey (orange), Loxleigh (antique) and Burford (brown) with their own handmade fittings range.

Daniel Redfern, product manager from Marley Eternit, comments “We developed the Canterbury range specifically for projects like this, giving architects and self builders more choice when only genuine handmade clay plain tiles may be specified to meet planning requirements. The traditional hand making process brings random undulations and variations that give each tile its unique appearance, creating a distinct rustic style roof that is ideal for conservation or aesthetic purposes.”

For more information, literature and samples, please contact 01283 722588 or visit www.marleyeternit.co.uk/handmade
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Genuine handmade Brookhurst Wentworth clay roof tiles at beautiful Hever Castle

Hever Castle & Gardens, in the perfect setting of the High Weald of Kent and once the seat of the Bullen family, is now also home to the Brookhurst Wentworth natural clay roof tile. It has been specified for the refurbishment of a variety of buildings in the grounds of the Castle including the Courtyard Shop and Head Gardeners offices, both adjacent to the romantic lakeside Loggia and newly refurbished Guthrie Pavilion restaurant.

Spanning more than 700 years the history of Hever Castle is both rich and varied. The original medieval defensive castle, with its gatehouse and walled bailey, was built in 1270. The double-moated castle was the seat of the Bullen family from 1462 – 1529 during the Tudor dynasty and the childhood home of Anne Boleyn, second queen consort of King Henry VIII of England. The Castle later came into the possession of his fourth wife Anne of Cleves.

“The roof tiles look really very good indeed and blend beautifully within this established site,” comments chief executive Duncan Leslie, Hever Castle Limited. “In fact, the roof tiles used on a more recent building adjacent to the refurbished Courtyard Shop are quite inappropriate by comparison. Eventually we would hope to replace them with the Brookhurst Wentworth.

“This tile has an authentic hand crafted appearance which immediately looks far better than the more commonly available machine made versions. It would have been very expensive and difficult to source a number of authentic reclaimed tiles to complete this project so the Wentworth is a great find.”

Brookhurst tiles are made from the highest quality clay material using traditional hand moulding and coal firing techniques. Whilst these glorious traditions are maintained, Brookhurst tiles meet the highest technical standards and are fully compliant with BSEN 538 and 539 test standards for strength, durability and weather protection.

“This is another successful project on which the Brookhurst hand-made tile has been specified and we are proud of the traditional aesthetic that it has helped to create,” says Iain Webster, director of Sahtas UK Limited, distributor of Brookhurst tiles, bricks and paviours. “It is a small project by many standards but few have this hallmark of authenticity.”

Brookhurst clay roof tiles are hand-made following the traditional methods that have evolved since the 3rd millennium BC. Blocks of selected clay from a private quarry are thrown on to sanded wooden moulds, cut, flattened and shaped by skilled hands. The tiles are fired in coal-fired kilns at 1070° for more than six days and then cooled slowly.

The soft sand granulation on the tile surface allows the tiles to weather and mellow rapidly; this aging gives the impact of a matured roof in a very short time. The artisan skills of Brookhurst production has also founded a vast inventory of bespoke designs, intricate and unique shapes and varied components with refined colour matches essential where extensive renovation is undertaken with conservation regulations in place. Brookhurst offers this bespoke facility alongside the high quality, high capacity plain tile supply chain.

Brookhurst tiles reflect the elegance of tradition coupled with the highest technical performance worldwide. They exceed frost test standards to offer over 100 years of protection, supreme flexural strength test standards, and advanced permeability testing, to provide a waterproof building with a 30 year manufacturing guarantee.

Polegate Roofing Limited, East Sussex, a specialist roofing contractor serving the counties of Sussex and Kent and a member of the Guild of Master Craftsmen, carried out the tile application. “We take on all types of tile and slate roofing projects and specialise in re-roofing works to older properties such as churches, manor houses, period and listed buildings,” says Ian Mepham, director.

“We were immediately impressed with the colour, quality and durability of the Brookhurst tile, not to mention an extremely competitive price. We have increasingly specified the Wentworth since using it on the Hever Estate and we always receive good feedback which we attribute to the aesthetic of the tile. The Brookhurst range of tiles and fittings blend well with reclaimed tiles, blending old with new, for a weathered and authentic appearance, even to new roofs.”

Of note the Astor family were owners of Hever Castle for 80 years from 1903 and made many important and notable additions, in particular that of the the Astor wing and the Anne Boleyn Wing, originally the Tudor Village, which is attached to the Castle and connected inside. The Village was commissioned by American millionaire William Waldorf Astor.

More product information is available at www.sahtas.co.uk. Alternatively telephone 01908 311411 or email sahtasuk@sahtas.com
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SFS intec extends support with structured BIM data for fasteners

Architects and designers working on BIM projects can now benefit from information on fastening solutions for the building envelope with ease, thanks to the ready-to-use structured data on the most widely used roofing and cladding fasteners now available from SFS intec.

The structured product data published exclusively by SFS intec, the world’s leading fastener manufacturer, is available to download at www.sfsintec.co.uk and is the first stage of the company’s initiative to provide a comprehensive library of product information to support BIM Level 2. It represents another dimension to SFS intec’s market-leading support for specifiers and contractors which already includes easy to reach, UK-based Technical and Specification Teams offering on-demand expertise to help achieve the highest performing building envelopes.

Andy Stolworthy, Product and Market Development Manager at SFS intec, says “We believe that through standardising data, clients and project teams will be able to compare and select products based on value and life cycle benefits rather than just price. This should allow for better quality products to be selected, so that life cycle costings reduce. It is obviously a far more sustainable approach to construction and something that resonates with our values at SFS in terms of delivering higher quality buildings.

“The fastener plays a fundamental role in the roof or façade system, but with current working practices and BIM software technology we believe at this time that a 3D BIM object would not be as widely beneficial as structured data. This presents product information in plain language with simple questions and answers allowing integration into a greater system element, be that data or 3D geometry. That’s why we are leading the way, by developing data for our products that can be used now.”

In addition to CAD drawings, ETA and Technical Value sheets, SFS intec has defined its own structured product data template, initially for self-drilling fasteners, with five Structured Data Sheets available for fasteners SL2, SX3, SX5, SXC5 and SXC14. These data sheets provide information content that defines the product, its properties and functional characteristics. The Data Sheets are available in PDF format for free download from www.sfsintec.co.uk, with Excel files also available by request from gb_technical@sfsintec.biz.

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Midland Lead ahead of the game in environmental standards with new ISO 14001 accreditation

Leading British lead sheet manufacturer Midland Lead is one of the first in the lead industry to have been awarded the new ISO 14001 2015 Environmental Management accreditation by the British Standards Institution (BSI).

With a high commitment to reducing environmental impact, the company received the updated ISO ahead of schedule in December 2016, having only been audited by the BSI the previous month.
Initially accredited ISO 14001 in 2006, the internationally accepted standard outlines the most effective ways to put a successful environmental management system (EMS) in place.

In a bid to support emissions reductions in the UK, Midland Lead’s recent improvements include investment in a new energy efficient crane for the company’s refining plant, truck upgrades, purchasing five Autogas (LPG)-operated forklifts, which reduce CO2 exhaust emissions, and replacing halogen light bulbs with LED light bulbs across the factory.

Midland Lead’s managing director Boudewijn Tuinenburg says: “It’s fantastic to have been awarded the updated ISO so soon after being audited.

“This certification delivers more than regulatory compliance and the ability to meet supplier requirements. ISO 14001 also helps us make our day-to-day operations more sustainable, which as well as being great for the environment, also saves the business money and engages our employees.”

Introduced in July 2015, one of the major changes to ISO 14001 2015 is a focus on identifying lifecycles, with the aim of getting organisations to consider their wider impact, from cradle to grave, by using their environmental influence throughout their supply chains.

In addition to Midland Lead’s factory and supply chain improvements, the ISO’s updates align with the very nature of the company’s lead sheet product, which is expected to last more than 60 years and is made from 100 percent recycled lead.

With the Government’s 2020 drive for vehicles to be more energy efficient, ISO 14001 also encourages a positive ethos of continual improvement. “As a company, the environment is in the forefront of our minds with everything we do and we’re committed to becoming as energy efficient as possible,” says Boudewijn.

“So while we have passed this audit with flying colours, there is always more that can be done to decrease our environmental impact,” he explains, adding that the firm is currently exploring new technologies such as heat exchange and gas turbines to further maximise the way in which energy is used in manufacturing processes.

Furthering their commitment to reducing environmental impact, Midland Lead’s risk and performance manager, Diane Rainsford, recently passed her lead environmental auditor training. Accredited by the Institute of Environmental Management and Assessment (IEMA) and the International Register of Certificated Auditors (IRCA), this qualification allows Diane to audit all of the company’s suppliers, ensuring products are of a high quality and minimise damage to the environment.

For more information please visit www.midlandlead.co.uk
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Floor screeds made simple with Saint-Gobain Weber’s YouTube video

Saint-Gobain Weber takes training in the specification and application of their innovative, market leading materials responsibly. A team of technical advisors is available to support and advise, either over the telephone or on site, on the correct use of a diverse product offering.

“In addition to the Saint-Gobain Technical Academy here in Bedfordshire, one of several across the country,” says Rob Speke, training academy manager, Saint-Gobain Weber. “We now have a wide inventory of How To videos posted on YouTube for specifiers and applicators who are unable to attend a related course at the Academy.”

How To videos have been created to address the most frequently raised technical enquiries received by Weber’s technicians for tile preparation, flooring products, renders and external wall insulation systems.

Watch the video here.

A popular and frequently viewed Weber video identifies the many benefits of the weberfloor 4310 fibre flow floor screed. This fibre-modified material is formulated from special cements, aggregates, supplementary binders and chemical admixtures. Designed for quick, efficient and effective pump application weberfloor 4310 fibre flow has excellent spreading and smoothing characteristics. It is supplied as a pre-blended dry powder and only requires the addition of clean water on site.

“The versatile weberfloor 4310 fibre flow screed is designed for covering a variety of substrates including tiled, carpeted, flexible floor coverings and even parquet flooring,” says Rob Speke. “One of its greatest attributes is that it can be applied at thicknesses between 5 – 50mm in comparison with 100mm of a traditional concrete screed. It is also ready for covering after 1 – 3 weeks in comparison with a concrete equivalent which takes 5 – 7 weeks.”

Manufactured under BSI Quality Assurance Scheme ISO 9001, weberfloor 4310 fibre flow can be used in domestic and commercial applications. It has low alkalinity, is low in emissions and is casein-free.

This How To video is one of 30 currently hosted on YouTube with plans for many more over the coming months. For more information, or for technical support, please contact Saint-Gobain Weber on 08703 9335 2999, or visit www.netweber.co.uk. Customers in Ireland should call 028 9335 2999 or visit www.weber.ie.

A free download of the new weber.app for iPhone and iPad users is also available from iTunes and from Google Play for Android smartphones and tablet users. Follow Saint-Gobain Weber on Twitter @SGWeberUK for the latest company news and updates and look out for more introductions of new How To videos.

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Aggregate Industries Keeps it Light for High Rise Apartments

Aggregate Industries’ Lytacrete solution was the product of choice when it came to helping to introduce an additional floor mid-construction at a new seven story upmarket apartment scheme in Southampton.

Located on Albert Road South, Southampton, the luxury apartment block was originally conceived as a six story scheme. Part-way through construction, plans were redesigned to include an additional floor – creating 20 apartments (7 one bedroom, 12 two bedroom and 1 three bedroom) for the area.

The challenge for Wright Investments was to include another floor without overloading the existing structure that was already in place – no easy feat. However, fortunately this was made possible with the help of Aggregate Industries who suggested Lytacrete – a specialist lightweight solution – in place of conventional weighty concrete.

Helping to revolutionise modern construction, Lytacrete concrete, which is formed using Lytag secondary aggregate, can be up to 50 per cent lighter than traditional comparable materials.
As such, by using Lytacrete, Wright Investments will be able to reduce the dead load of the construction by approximately 7620kN over normal weight concrete whilst maintaining its structural integrity. Crucially for the project, this has enabled reduced size columns, beams and slabs, allowing greater room the developers to add the additional required floor.

Steve Curley from Aggregate Industries comments: “Changing the original design plan mid-way through construction is common, but can present a series of challenges for the contractor. Although there were a number of traditional alternatives available, the use of Lytacrete eliminated the need for expensive re-structuring works to support an additional floor, which most importantly helped keep the project to budget and schedule.”

In production for more than 50 years, Lytag secondary aggregate is made using innovative technology which transforms fly ash into small pellets which are then heated to 1,100°C. The pellets formed are rounded in shape and range in size from 14 mm down to fines and can be used as a superior, consistent, lightweight aggregate.

In total, 420m3 of Lytacrete was supplied for the completion of 7 storeys in the Albert Road South apartment scheme, due for completion in 2018.

For more information on Lytag call 01904 727922 or visit www.lytag.com
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By the seaside with Kingspan Kooltherm

The premium performance of the Kingspan Kooltherm K108 Cavity Wall Board has led to its specification on a new residential development in Hendy, North West Swansea, helping the project to meet its thermal performance requirements with a slim construction build up.

Situated in one of the most desirable postcodes in Wales, Cwrt Y Bedw is a collection of 82 two-, three- and four-bedroom homes, including 19 affordable homes, being constructed by Persimmon Homes West Wales. With an intimate village location and easy access to the region’s beautiful coastline, the development has been designed with first-time buyers and families in mind. In order to ensure the dwellings were as energy efficient as possible, Persimmon Homes used a variety of techniques and cutting-edge technologies throughout the project, including Kingspan Kooltherm K108 Cavity Board.

Carl Davey, Construction Director at Persimmon Homes West Wales, explains “The Kingspan Kooltherm K108 Cavity Board provided the technical solution we needed to easily secure a compliant level of thermal performance, within a standard cavity depth, at an economical price. Our site teams found the product clean and easy to install and we were impressed with both the product’s features and the quality of the installation we have achieved at the Cwrt Y Bedw scheme.”

Kingspan

Part of Kingspan’s new Kooltherm K100 range, Kingspan K108 Cavity Board features a fibre-free phenolic core with an outstanding thermal conductivity of 0.018 W/m.K. This excellent performance enables housebuilders to meet or exceed target external wall U-values, without encroaching on living space or moving away from preferred cavity sizes. 460 m2 of Kingspan Thermapitch TP10 was also installed on the slated pitched roofs of the new homes, providing a high thermal performance of 0.022 W/m∙K.

All Kingspan Kooltherm, Therma and KoolDuct insulation products and cavity closers manufactured at Kingspan Insulation’s facilities in Pembridge and Selby are certified to BES 6001 (Framework Standard for the Responsible Sourcing of Construction Products) ‘Excellent’. The products are manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP).

For further information, please call 01544 387 384, email info@kingspaninsulation.co.uk or visit www.kingspaninsulation.co.uk.
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