Cold-roll renaissance

Technical Editor Bruce Meechan visits Britain’s traditional ‘metal-bashing’ heartland to discover how one company is giving steel framing a very modern ring.

Having paid a brief visit to Metsec’s stand at the Offsite exhibition prior to Christmas, I accepted an invitation from the company’s Marketing and Business Development Director to visit the premises at Oldbury in the Midlands: to find out more about its divisions which embrace dry-lining systems and cable management systems as well as high performance purlins and light gauge steel framing for all types of building structure.

Despite the company’s strong performance over recent years – defying the downturn in construction after the financial crisis – Richard Allen still sees two rather illogical barriers to even better growth figures, which he is trying to address.

The first came to light during a series of focus group meetings involving industry professionals. These revealed that the name ‘Metsec’ is commonly used in construction as a verb or generic term – including by some people who didn’t know the manufacturer actually existed.

The second, though, could be easier to understand, given the construction trade’s notorious reluctance to adopt new practices: even when there are many good reasons for doing so. Richard reflected: “Despite the potential for steel framing to save them time, cost and hassle, some people still perceive there is a risk to using a non-standard method of construction. Their reluctance to adopt modern methods of working – normally by reverting to in-situ concrete – means they are missing out on the cost and programme savings which could be afforded to them. The lightness of the Metframe system can allow you to employ shallower foundations as well as offering great acoustic, thermal and fire performance. And overall you can just build that much faster than with a reinforced concrete frame.”

So how does the Metsec offering deliver these many benefits? “When you look at the products that we sell,” Richard explained, “in essence there is nothing that complicated about them. Our Metframe system for instance features cold-roll formed C and U-sections; the complexity comes in understanding how they work together to create a 12-storey structure.

“It is very much in our design capabilities that we add value for our customers, and why Metsec has come to be regarded as a thought leader within the sector. We have some very clever engineers using the latest design software: including TEKLA and Revit.”

Responding to the industry’s bilateral use of UK and European standards, Metsec’s software allows projects to be designed in line with either the British Standard or Eurocode. Its range is also CE marked to Level 4.

He continued: “When it comes to our purlins systems we aim to make the structural engineer’s life easier, offering them free software for designing the different systems. For instance inputting the building’s location will automatically take account of typical snow load and wind loading for the area. Then given the building’s dimensions it will calculate the most efficient purlin design, using the optimum amount of steel.

“Then for the fabricators, they want something which is easy to erect; where the logistics are in line with the build programme. Because we operate on a very short lead time, we can adjust delivery dates to match any problems they might have with the weather or variations from the client.

“It is design expertise which enables us to carry out all of our contracts in such a way that we can create cost savings for our customers. Take for example Smithfield in Manchester – our ability to map out the full elevations to the building for the client, and seeking ways to value engineer the design meant we were able to remove a considerable amount of hot rolled steel – offering Galliford Try real cost savings. Elsewhere our lightweight steel framing systems have had a lot of success using our infill walling system with student accommodation as well as a number of social housing projects: and we are keen to do more.”

Across all of its different divisions, Metsec’s interaction with consultants and clients is led by its specification sales teams, all of which – with the exception of dry-lining – are split up regionally.

/0 Comments/by

Triple timber solution to sustainability

,

Technical Editor Bruce Meechan looks at the range of very low carbon solutions available from a major timber frame manufacturer based on the Shropshire – Mid Wales border.

As an offsite manufacturer working across a variety of sectors including commercial, residential and education, Lowfield Timber Frame is well used to being presented with different technical challenges; and to meeting them through the use of different solutions that reflect the versatility of what is arguably nature’s most versatile material.

In essence, Lowfield has in recent years, responded to the demands of both clients and architects for PassivHaus and Near-to-Zero carbon buildings employing twin-wall timber frame, structural insulated panels (SIPs) and now a closed panel system based on timber I-joists.

Darren Jarman, Managing Director for Lowfield Timber Frame, told MMC Magazine: “We have an extensive product range that enables us to respond to clients targeting PassivHaus standard or other very low energy solutions; and we will work with their architects and assessors or other specialist consultants in order to ensure all the details – such as the floor wall junction or foundation connection, achieve the required levels of insulation.

“Some ten years ago we supplied a twin-wall timber frame system for the principal of Munro Associates who was building a new home up in Pitlochry, Scotland. That achieved the level of U-value necessary for PassivHaus – by filling with Warmcel recycled newspaper insulation; and now we are working with PYC Warmcel on a solution featuring 300 mm thick I-joists supplied by Metsa Wood for a social housing scheme featuring low rise homes. We have also built to PassivHaus standards using the Kingspan TEK system; so our product range can really cover all the bases and offer clients solutions to suit their individual needs.”

The architect, Mungo Munro commented: “We do a lot of work for housing associations as well as clients in other sectors, though this was a self-build where Lowfield produced a timber frame to my own design. I went for a double timber frame as it virtually eliminates any cold-bridging and achieved a U-value far better than the Building Standards required.”

Amongst the other highly sustainable projects Lowfield Timber Frame has helped deliver recently is the Telford Town Park Visitor Centre, offering bicycle hire and a café as well as classroom space. The original intention was to build the walls from straw bales, but the cost would have pushed up the budget so the specification switched to the Kingspan TEK system.

The jointing arrangement for the SIPs system helped keep the air leakage rate to around 1 m3/m2/hr at 50 Pascals. The addition of a high performance vapour control layer as part of the building envelope meant the overall airtightness figure for the finished structure outperformed the PassivHaus requirement at 0.58 m3/m2/hr. In terms of insulation value, combined with Kingspan Thermawall TW55 boards, the U-value for the Tek walls was 0.14 W/m2K.

Lowfield also contributed to the conversion of an eyesore, asbestos-clad packing shed into a stunning studio on the outskirts of Leamington Spa; which earned the architect, Sjolander de Cruz, the RIBA Sustainable Project of the Year Award.

/0 Comments/by

G-frame engineered timber and hybrid structures

G-frame Structures specialises in the design, supply and installation of engineered timber and hybrid structures. A designer of bespoke solutions, G-frame Structures offers a direct route to a complete hybrid package working with a palette that includes Cross Laminated Timber, Glulam, Laminated Veneered Lumber. We are also able to meet your other structural solutions using more standard construction materials through our sister company Murform Ltd.

Involve us early in the design stages and we’ll help you to make savings from the outset and deliver your project ahead of programme with safety first and inside budget. We can also advise and help you to interface with a range of other systems, we are able to design and install timber cladding panels and insulated render as part of our water proof envelope package.

Known by our partners and clients for our hands-on approach to problem solving and fast, efficient delivery, the G-frame team brings a high degree of multi-disciplinary expertise and a commitment to building lasting relationships which leads to repeat business. We provide solutions across the range of building types including social and private residential, education, public access and workspace. Recent projects include the new Moneypenny HQ in Wrexham by AEW Architects, 150 London Road by Stephen Davy Peter Smith Architects and Graveney School 6th Form Block by Urban Projects Bureau which has recently won two awards at the 2016 RIBA London Awards.

All wood products are PEFC or FSC certified.

For more information please email Joe Hall at j.hall@g-frame.co.uk, call us on 01525 288022 or visit www.g-frame.co.uk.

G-frame Structures will be at VISION 2016 at Earl’s Court on 7 & 8 June – come and see us on Stand Number 105
/0 Comments/by

World-class sixth form centre built using offsite construction methods

The Sunday Times’ International Baccalaureate school of 2014 has been working with offsite construction specialists, Actavo | Building Solutions, to create a sixth form study centre to meet the school’s need for a world-class facility.

Tonbridge Grammar School in Deakin Leas, Tonbridge, gained access to its modular building after just 26 weeks onsite, to meet the demand for pupil places quickly and efficiently.

Designed to inspire and motivate pupils, Actavo created the ‘IBarn’ – a brand-new, two-storey, sixth form hub created to improve pupil facilities and respond to rapid student growth. The ground floor of the new sixth form includes a café, collaborative learning areas and changing rooms while the first floor comprises an ICT suite alongside two large spaces that can be used as classrooms, independent study, seminar areas or opened up for lectures and presentations.

The IBarn also frees vital space in the existing sixth form accommodation to enhance student development.

Matthew Goff, UK operations director at Actavo | Building Solutions, said: “Perhaps the popularity offsite construction has in the education sector is due to its speed, versatility and cost-effective nature.

“The competitive funding mechanisms and demand for school places at Tonbridge Grammar School meant tight deadlines enhancing the school’s need for speed.”

As part of the tender process, Actavo | Building Solutions developed a 3D animation to enable the school to visualise how the new facility would look once complete.

“As one of the UK’s top performing international baccalaureate schools, it was imperative we had a sixth form study centre that met the needs of the internationally minded curriculum. Actavo has helped us achieve this with the creation of the ‘IBarn’,” says Rosemary Joyce, Tonbridge Grammar School’s Head Teacher.

“Actavo has provided us with a sixth form facility that has the perfect balance between form and function. The contemporary feel of the ‘IBarn’, careful use of glass provides both students and teaching staff with an open, spacious and well ventilated space which supports the focus on collaborative, independent and reflective learning that is a feature of our school.

“The study centre also provides the ideal learning space for those preparing for university and enabled refurbishment of the vacated classrooms, facilitating more flexible space for our talented musicians.

“As well as being architecturally attractive, our new modular facility is an aspirational space to both work and study. Proving the cost-effective and speedy solutions offsite construction offers in no way takes away from the quality of the final building,” says Rosemary.

To view our exclusive walk-through and video testimonial from Tonbridge Grammar’s head teacher, Rosemary Joyce, please click here.
/0 Comments/by

Building Transformation: School Urban Transformer Grants

This summer, we’re offering three Secondary or Upper schools the opportunity to take up one of our sensational School Urban Transformer Grants. In each week-long program in the summer holidays, Building Transformation will provide the tools, training and expert knowledge to transform your school environment with founding partner Reece Wood and his expert colleagues.

The program, for six enthusiastic students, will offer a fun, skill-building opportunity to engage with, develop and improve their school’s space, as well as offering the following skills:

  • Environmental evaluation
  • Developing a plan of action
  • Selecting and meeting deadlines
  • Performing risk assessments
  • Analysing and understanding safety checks and construction plans
  • Taking instructions from supervising experts
  • Working as a team to produce agreed results

All these skills and more will be developed by the staff of Building Transformation, at no cost to the participating schools. All safety equipment and materials will also be provided by Building Transformation.

“When I pick my own kids up from school, it’s obvious that the classes enjoy activities most in those well-maintained, well cared-for areas; I can see how the school environment has a direct affect on their engagement with it. Any external building fabric plays a big part in influencing the emotions and even behaviour of the building users: a school landscape should be positive, feel safe and reflect the school’s culture and values, as a space that inspires students and teachers and makes them proud.

“However, maintenance issues can be costly, and low on the list of concerns as more pressing items taking priority; problems are often allowed to build and impact the school’s environments, negatively influencing students’ feelings about their school over time. This can result in an imbalance between the core values of a school, and its physical appearance. The problem isn’t down to people not caring, but rather that both budgets and time are limited.

“Yet the simple solutions that make a real difference to the quality of a school environment shouldn’t be expensive or difficult to access. Algae, carbon, environmental pollution, chewing gum & graffiti, are all easily removed with the correct equipment and approach. This year we aim to give the know-how and control back to schools and students, to help create school environments of the future. The School Urban Transformer Grant is our way of making a difference in our own communities.

“We want to create a fun programme, that builds the students’ skills, values and education, plus uses their enthusiasm and energy to give something back to the school environment that has helped shape their future, at no expense to the school. And by developing and completing the process with the students, they’ll take ownership of their space, feeling more protective, and viewing it with a new set of eyes.

I’d love to hear your thoughts — please get in touch, and I can answer any questions you might have.”

What is the purpose behind the School Urban Transformer program?

“To work with three schools for one week each, to help them create a more inspiring, valued and more sustainable environment that they are proud of and is in line with their standards of performance; to breathe new life into the tired or challenging-to-manage school environment; and to give the knowhow, pride and ownership back to the students, and back to the school. We want students and schools to feel that the cleaned and restored environment is a closer reflection of their values, ethos and vision.

“The grant includes one week’s Urban Transformation program within your school, as well as one day’s initial planning and development three to four weeks prior, working with your chosen students and your school’s maintenance staff.”

Why is Building Transformation doing this?

“We’re constantly thinking how we canwhat make real difference, both to environments and people, by bringing to life the real purpose of our business with our skills and assets. Having been asked to provide solutions to schools over the past few years, having looked at the varying condition of school environments, listened to the issues around budgets and maintenance limitations, pressures, priorities and how all of this impacts on the school, we believe that we can give schools the knowhow and solutions they need to create an environment and space that fits with their ethos and vision for the future.

“It’s important to us to help create communities of people that take ownership and pride in their environment.”

Who is Building Transformation?

“We’re an international building façade maintenance and consultancy service, working with major industry and education institutions across the UK and abroad, with over 15 years’ expertise in design, environmental sustainability and building regeneration.”

What do the schools need to do?

“Complete the application form by 17th June. The chosen schools will need to select six Y12 students who have the enthusiasm and energy to take part in the program for a week during the summer holidays, and who will be eager to learn new skills and develop their CVs and UCAS applications while also protecting their school environment for the future.”

For more information please visit www.buildingtransformation.co.uk/schools, email schools@buildingtransformation.co.uk or phone 01234 964 019.
/0 Comments/by

Rinnai – on demand hot water heating units on LPG is low NOX, sustainable and perfect for off-grid hot sites

Rinnai’s range of condensing hot water heater units using LPG are more economic to run than other sources such as oil or electric counterparts and they deliver lower carbon emission figures, greater energy efficiencies – this makes them the first choice for off-grid installations.

For installers, helping an off-grid user select an energy efficient water heater is critical — and a condensing continuous flow water heater using LPG is one of the most efficient and environmentally friendly options available. By choosing a continuous flow water heater, an end user can reduce energy costs by up to 50% and reduce greenhouse gas emissions by up to 61% (compared to electric equivalents). When compared with oil-fired systems this saving is even greater.

Tests show that a Rinnai Infinity condensing water heater has 107% efficiency and is low NOX compared with an oil boiler that emits approximately 364 mg/kwh NOX. That means a Rinnai condensing water heater emits approximately 10% of the NOX that an oil boiler emits, a 90% reduction. Therefore, combining a gas boiler and a Rinnai water heater will radically reduce NOX.

The EU is recommending that the maximum NOX level be reduced to just 56mg/kWh by 2018. Rinnai water heaters are already compliant with this proposed standard. This forms part of the new rules under the Eco-design of Energy-using Products Directive (ErP).

If we now compare the production of CO₂ between gas and electricity we find that for every GJ (277.78kW) of energy used gas will produce 44.44kg compared to 103kg with electric. We can see that for the same energy used electricity will produce twice the amount of one of the major greenhouse gases.

Then if we look at the emission per kW from thermal generation of electricity we find that electricity will produce 0.5kg of CO₂ compared to 0.16kg for the same kW generated with LPG, NOX production works out at 258kg per KW as compared to only 0.184kg.

The efficiency of this type of electrical generation is as low as 40%. So if we now compare the use of electricity to LPG to heat hot water we find that electricity is 40% efficient in comparison to a Rinnai water heater which returns 107% efficiency.

Electricity is not the ‘green’ fuel that its marketing portrays it to be. It has potential to produce more CO₂ and NOX and can be very costly.

A Rinnai LPG continuous flow water heater is an ‘on-demand’ system. When a hot-water tap is opened, the unit reads the demand and starts the heating process. The water flows through a heat exchanger, where it heats to the desired temperature using only as much gas as is needed. When the tap is turned off, the heater automatically shuts off.

For more details on RINNAI products visit www.rinnaiuk.com.
/0 Comments/by

Sikafloor makes the grade at Welsh bottle plant

For a new production line floor at a bottling plant in Wales, a specialist floor surface system from Sika has delivered long term performance and excellent durability whilst meeting the demanding hygiene regulations within the food and drink industry.

The Radnor Hills Mineral Water Company in Knighton produces more than 175 million bottles each year. For a new bottling line, the floor surface had to meet industry standards, withstand heavy machinery and be easy to clean. Appointed to complete the application within the limited timeframe, specialist contractor Coatech turned to Sika and the company’s Sikafloor PurCem polyurethane resin system – a market proven high strength screed.

Following the re-screeding and sloping of an old warehouse floor to ease cleaning and drainage, Coatech diamond ground the screed to provide an effective key for the application of 100m2 of Sikafloor Purcem 20 which was laid to a depth of 9mm. The Sikafloor system was also used as a seal coat for covings, ensuring ease of cleaning and hygiene.

Offering excellent strength, Sikafloor 20N Purcem is a polyurethane modified cement screed that is highly resistant to chemicals, fatty acids and temperature. As the water-based system normally requires no primer, its installation is considerably less complex than many other systems, producing a joint-free surface that is slip and abrasion resistant.

Sika’s range of flooring systems for food and beverage production areas meets and exceeds client expectations, industry best practices and building regulations and legislation. All Sika flooring specifications are available via NBS+ and are supported with comprehensive technical support.

Now complete, the finished production floor at Radnor Hills Mineral Water can be steam cleaned to maintain the highest levels of hygienic surface demanded by the modern food and drink industry.

The careful and considered choice of product perfectly demonstrates how Sikafloor systems can help deliver high performance and cost-effective solutions for the most challenging and innovative commercial applications.

For more information please call 01707 394444, or visit www.sika.co.uk.
/0 Comments/by

Small and Mighty – GEZE UK Launches a Tiny Powerhouse

It may be small but it packs a punch! The launch of GEZE’s new sliding door system is a real David and Goliath affair. The Levolan 120 belies its modest appearance – the slimline fitting can effortlessly move internal doors of up to 120kg with elegant ease.

It has twice the load-bearing capacity of its “little brother”, the Levolan 60 which won the Plus X Award and was named the Best Product of 2014, in its category.

The Levolan 120 shares its discreet aesthetic: with straight lines and modular composition, it’s a system which is highly adaptable. Its sleek track, which is only 50mm high, includes integrated derailing protection and can be conveniently installed from the front.

This means that large panelled sliding doors – made from glass, wood, metal or plastic – which have interior design impact and a real “wow factor” can be put in place in the knowledge that their practical application can be effectively managed.

Additional safety is provided by the Levolan 120 SoftStop draw-in damping device which can be incorporated into the track as an option. The sliding door leaves are gently guided into their end position with little possibility of anything hitting the frame or risk of fingers being trapped.

The system has specially designed roller carriers which ensure outstanding load distribution enabling the leaves to move easily and almost silently. Its derailing protection is triggered automatically when the height of the door leaf is adjusted, ensuring that the best possible level of opening and closing is provided.

The clamping roller carriage is designed for glass thickness of 10 – 12.76mm which allows the Levolan 120 to be installed with door leaves made of laminated safety glass.

Its compact dimensions make is extremely versatile meaning it can be installed on a wall, suspended from a ceiling or glass fanlight or invisibly mounted within a ceiling.

The Levolan Smart fix installation system makes fitting fast and straightforward – just one Allen key and one open-ended spanner are needed to set the height of the cam – and the leaf and roller carriage can be mounted on the track and calibrated from the front.

Due to its modular composition, the Levolan 120 can be provided as ready-made sets configured to the customer’s needs or as individual parts.

The modular construction of the Levolan system also means that the parts for the Levolan 120 and the Levolan 60 are interchangeable – reducing the number of parts required for installing sliding door leaves of different weights and sizes.

Andy Howland, sales director of GEZE UK said the Levolan 120 was a “tiny powerhouse” capable of moving large sliding doors “easily and effortlessly”

“This Levolan 120 is an evolution to our existing award-winning interior sliding door system, with a phenomenal load movement capacity, modest in size and near silent in operation. We are confident that this product will be the ideal solution to large door leaf requirements which are currently very popular within contemporary interior design schemes.”

For more information about the Levolan 120 and GEZE UK’s comprehensive range of automatic and manual door closers call 01543 443000 or visit www.geze.co.uk.
/0 Comments/by

Introducing the New Bond

Acting on intelligence out in the field, undercover fixing specialist Ancon has launched a new super-Bond, ultra-low thermal conductivity wall tie that even SPECTRE would find hard to crack!

Based on the company’s multi-award winning TeploTie with a conductivity of 00.7W/mK which virtually eliminates heat loss through thermal bridging in cavity wall construction, the new Teplo-BF basalt fibre wall tie features specially moulded safety ends that improve buildability and enhance mortar bond strength by up to 80%.

The new user-friendly design has exceptional mortar grabbing capability, making Teplo-BF particularly suitable for use with lime and other slow-drying mortars.

The Teplo-BF, like the original TeploTie which was introduced into the UK and Ireland by Ancon in 2010 and since used on a number of ground-breaking PassivHaus and Zero-Carbon buildings, is created by the setting of innovative pultruded basalt fibres in a resin matrix. This composite material provides a combination of high strength and outstanding thermal efficiency.

The ultra-low thermal conductivity, twenty times below that of stainless steel, means that Teplo-BF ties are excluded from U-value calculations to BS EN ISO 6946, helping to minimise insulation and wall thickness, a particular benefit in modern low-energy construction applications.

Available in the same wide range of lengths and types as the original TeploTie, the new Teplo-BF wall tie is suitable for cavities up to 450mm wide and buildings up to 18 metres in height, and carry BBA and NHBC technical approvals.

Ancon Marketing Manager, Annabelle Wilson, said “Following discussions with building contractors, Ancon identified a need for a more user-friendly design, offering a more robust bond that is better suited to the general site environment, and greater versatility in the choice of mortars with which Teplo ties can be used. The new Teplo-BF not only meets these requirements but the new moulded ends make these ties safer for bricklayers to work around too.”

“This range extension provides the market with three distinct Teplo options – the original TeploTie for new-build applications and resin-fixing into an existing structure during retrofit, the Teplo-L-Tie for surface fixing to an in-situ structural frame, and the Teplo-BF, an improved new-build cavity wall tie with high bond strength even in slow-drying mortars and moulded safety ends. Ancon’s comprehensive wall tie range includes a low thermal conductivity fixing for almost any masonry construction project.”

For more information please visit www.ancon.co.uk/products/wall-ties-restraint-fixings.

/0 Comments/by

The UK panelised modular building systems market grows by 10% in 2015

The UK market for panelised modular building systems is estimated to have grown by 10% in 2015. Since the recent market low of 2012, demand for offsite building systems has increased strongly, underpinned by the improved economic situation and increased levels of activity in the housebuilding, hotel, student accommodation and education sectors. This recovery followed a downturn between 2008-12 due a decline in the housing market, cuts in public sector budgets and the completion of major MoD projects.

AMA Research’s definition of this market consists of pre-fabricated, 2-dimensional frames or panels in systems for constructing walls, partitions, roofs and floors, typically supplied to site as systems in flat-pack format. However, some systems, particularly light steel frame, are supplied to site in ‘stick’ form and/or direct to manufacturers of volumetric building systems. The main product type is timber frame, which is competing with light gauge steel, precast concrete and other engineered wood-based panels, with the latter group including structural insulated panels and cross laminated timber systems. While timber frame is currently the most widely used type of offsite systems in housing, it is expected to face competition from cross laminated timber over the next few years.

Key end use sectors for panelised modular building systems are housing, apartment blocks, schools, budget hotels, smaller healthcare and care facilities, and purpose built student accommodation. With the exception of the MoD, where many projects are now complete, most of the key end use sectors for panelised modular building systems look set for growth over the next few years and a number of housing developers and housing associations have declared their intentions to increase usage of offsite systems.

“Difficult market conditions in recent years had led to all sectors of the panelised building systems industry suffering a number of business failures, leading to a reduction in production capacities, and market supply has become much more polarised, in particular in the timber frame sector” said Keith Taylor, Director of AMA Research. “However, the market has improved since 2012 and further sustained recovery is expected until 2020, driven by improvements in key end use sectors such as housing – including self build, which is significant in this market”.
Growth over the next few years should also be enhanced by the mandatory use of Building Information Modelling on public sector projects from 2016. BIM will streamline building design, procurement and construction which should favour the use of offsite building. The drive towards sustainable development, coupled with the need to meet energy efficiency and carbon reduction targets, would also seem to weigh in favour of offsite construction.

In addition, some of the key drivers for offsite construction are coming back into focus, with recent announcements of a number of larger scale, repetitive construction programmes, in sectors such as university accommodation, social housing, affordable private sector housing and budget hotels.

The ‘Panelised Modular Building Systems Market Report – UK 2016-2020 Analysis’ report is published by AMA Research, a leading provider of market research and consultancy services with over 25 years’ experience within the construction and home improvement markets.

The report is available now and can be ordered online at www.amaresearch.co.uk or by calling 01242 235724.
/0 Comments/by