This is MMC… but not as we know it

Advances in construction techniques over the past decade have given rise to some genuine commercial, sustainable and health and safety benefits – all while improving efficiency and performance. However, as building regulations are updated over time and standards become increasingly stringent, these modern methods of construction risk failing to keep pace, particularly where thermal insulation is concerned. Chris Lea, Technical Sales Manager, SIG Performance Technology, explores why the construction sector needs to rethink its approach to reducing heat loss in a building and why the aerospace industry appears to hold the answer. 

Some of the major specification drivers for building design in modern times are the need to keep building footprint to a minimum, maximise internal rentable space and achieve the highest energy efficiency performance possible. Working within the confines of these design objectives, developers must also achieve accelerated build programmes in a bid to complete within budget and realise the return on investment as promptly as possible.

Fast track construction which uses steel or timber frame has become a tried and tested build method in the UK, particularly in high rise developments. As the exterior of these buildings is commonly a cladding finish, the challenge of reducing heat loss while maximising internal floor space and minimising building footprint comes to the fore. Crucially, the insulation has to be installed within the through-wall build up, but this construction suffers from cold bridging as soon as the rainscreen carrier system is installed. This is where innovative new insulation techniques are helping modern construction techniques to stay at the forefront.

Helping hands

The availability of 3D thermal modelling has proven a valuable technology in assisting the development of new solutions which address current construction challenges. After reviewing thermal models of buildings using rainscreen systems, the innovation team at SIG Performance Technology identified high levels of heat loss being caused by the helping hand bracketry in the support systems. Realising that a reduction in the cold bridging through the bracketry would significantly improve the overall performance of the building envelope, research began into developing an insulated clip-on solution.

After a programme of development, aerogel – most commonly used in aerospace and industrial applications – emerged as the most suitable insulant owing to its exceptional thermal performance and proven flexible properties. This led to the launch of CHI-GASKET, a patented insulated component which is simply clipped on to standard helping hand bracketry on-site. In doing so, the cold bridging is significantly reduced and means the insulation within the through-wall build-up does not have to compensate for this and consequently does not have to achieve such low U-Values. It is because of this that the CHI-GASKET is now considered from initial design stage.

Aerogel in action

The use of Aerogel as an insulant in helping hand bracketry is a unique application but one where a change in design process has enabled major developments to achieve core design objectives. This principle is also now being applied in modular buildings and offsite construction, where linear areas of heat loss at construction junctions prove a common challenge.

As the modular buildings typically have much tighter junctions than those constructed on-site, these developments present several challenges. Firstly, lower density insulation is more flexible and easier to install into tight frames, but these materials are generally lower performing from a thermal perspective. Secondly, rigid materials offer good thermal insulation, but require cutting to size, either on or off-site, which adds a layer of complexity to the construction process. Finally, both of these methods leave room for installation error, as the materials are being cut to size or pushed into place manually.

Offering a solution to this challenge is Aerogel. The material can be precision cut to size and fabricated to any bespoke shape to meet the exact needs of modular building specifications. Thermally excellent yet flexible, precision manufactured aerogel linings would deliver a much greater level of quality control and reduce labour time in construction – all of which align with modern methods of construction.

While the name Aerogel is probably more synonymous with NASA than with MMC, as the construction market continues to innovate with insulation, this could be set to change in the not so distant future.

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High specification for a higher education building

Architecturally designed and built completely to spec, the new three-storey building on the University of Birmingham’s Edgbaston Campus is full of unique features.

New office space was required to accommodate University academics: overall growth and construction work elsewhere on campus meant that staff were temporarily displaced. Planning permission was granted for a new office block, but only for 3 and a half years.

Not Just a Temporary Solution

The brief: the building needed to be temporary but not feel temporary, and it needed to be spacious, contemporary and light. Time was of the essence, but without compromise on finish.
Of the three companies asked to tender by the University, Wernick Buildings were selecting as the preferred tenderer based on a combination of cost, quality and programme A Wernick Buildings’ modular system allowed the architects to customise the internal and external finishes while maintaining the budget and schedule.

A wide range of features were specified from the outset: from architectural features such as the large sections of glazing, feature banding and projecting window surrounds, down to the finishing touches of skirtings, window frames and doors. The resulting space is befitting to its prestigious surroundings and listed neighbouring buildings.

Modular Installation and Feedback

After just six weeks in the factory, the 36 modules were loaded and ready for the trip from South Wales to Birmingham. The February installation was on schedule: even after allowing for some of the worst snow this country has seen for some time! Crane trucks manoeuvred the modules through mature trees on the site – giving the final impression that the building had always been there.

Kevin O’Flaherty, Senior Project Manager at University of Birmingham is responsible for a portion of the University’s ambitious capital programme, from the inception to getting the keys. Kevin, alongside the architects, worked very closely with the team at Wernick Buildings saying that he was in touch almost every day as decisions had to be made so quickly. Kevin found the Wernick team to be “highly professional and always wanting to do the best job”.

Kevin remarked: “I often hear “it doesn’t feel like a modular building” – the extra touches have really made the space and feedback so far has been overwhelmingly positive from both staff and planning.”

Due to the nature of the modular system used, the University can choose to move the building: either keeping the current configuration or changing it completely. The modules are built to be stacked up to four-storeys high or reduced down to one-storey. Kevin, however, feels the building sits very comfortably in its existing setting.

Architectural Touches

Glancy Nicholls Architects Ltd, based in Birmingham and London, is a Royal Institute of British Architects (RIBA) Chartered Practice and was started in 2004. Wernick worked with the firm previously, also at the University of Birmingham. Wernick helped GNA to deliver a low impact building for researchers studying the surrounding woodlands. Read more about the BIFoR scheme here.

GNA architectural assistant Aiden Astle, who worked on the new office building, is excited about both projects’ potential to “challenge the misconception of modular buildings”. The office building, he added, is further proof of modular’s capabilities: “This project demonstrates that a limited time-frame doesn’t need to infringe on quality. This project has proven the flexibility of this method of construction and the results speak for themselves.”

For more information on modular buildings, click here, call 0800 112 4640 or email us here.
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Pegler introduces thick wall steel pipe press fitting range

As the momentum for using an integrated piping system for HVAC applications gathers pace, leading manufacturer Pegler is thrilled to launch a press thick wall solution to its ever increasing portfolio.

VSH PowerPress is a range of fittings and valves for use on thick wall steel pipes particularly in the HVAC market. “We are delighted to be adding another range to our portfolio. This really does mean that Pegler has become the only manufacturer to offer a truly integrated piping system. With our breadth of experience and knowledge we can offer solutions and products from plant room to bathroom and beyond,” said Phill Jackson Business Development and Marketing Director.

The VSH PowerPress range is set to rival competitors by its innovative design and engineered credentials. Suitable for a range of applications including heating, cooling, sprinkler, air and oil the range will connect steel systems including black steel, epoxy coated and galvanized. This system also combines the best press technology, for which Pegler is renowned, and negates the need for heat which provides all the associated benefits such as; clean joints, no flux requirement, faster install times and a safer working environment ensuring an easier installation overall. In addition, VSH PowerPress also incorporates a fail-safe leak before press indicator and advanced ‘O’ ring protection.

Furthermore, a comprehensive range of adapted valves have been specifically designed to complement the system including, Gate, FODRV, Venturi DRV, PICV, Swing Check, Double Check, PRV and Strainer. In order to fully appreciate the requirements of such integrated piping systems Pegler has also developed a new ball valve range with lever and extended levers.

Phill continued: “We understand the demands on specifiers when sourcing a highly efficient system and by providing a comprehensive range of valves to support the building’s needs is something we are equipped to do whether that is via our existing products or developing new.

“By listening to both specifiers and installers we have developed a ball valve range for VSH PowerPress with specifiable features which greatly assist during the installation and maintenance phases.”

The innovations behind the new VSH PowerPress ball valve range include; colour switch inserts for recognition of hot or cold water service improved ergonomic handle supporting ease of use and a lockable latch enabling permanent or temporary fixing of valve in open or close position. This is all compounded by a strong and consistent identity found within all Pegler engineered valves.

The entire VSH PowerPress range has a working pressure of 16 bar, its temperature range EPDM is -40°C to 135°C and is Zinc-nickel plating surface protected which is suitable for outdoor usage. Sizes available from ½” to 2”.

For further information please contact: Tel: 01302 560 560 Website: www.pegleryorkshire.co.uk
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Ibstock Brick celebrates best of brick at Brick Awards

Ibstock Brick is celebrating the success of architects and brick contractors at this year’s Brick Awards.

The annual awards ceremony, organised by the Brick Development Association (BDA), saw three outstanding projects using products from the Ibstock Brick range named as winners, with a further two projects receiving commendations from the expert judging panel. Ibstock Brick also proudly sponsored three awards; Individual Housing Development, Architect’s Choice and Supreme winner.

The Architect’s Choice Award was voted for by the public from a selection of shortlisted projects in other categories. It was awarded to the BPTW Architects designed project at Creek Road in the heart of Greenwich. The project utilised the Funton Old Chelsea Yellow brick to mirror the existing bricks whilst adding a contemporary twist.

Marlborough Primary School (Architect: Dixon Jones) was the winner in the Education category whilst Royal Albert Wharf was the winner in the Large Housing Development category with Blackfriars Circus also picking up a commendation in this category, with both projects being designed by Maccreanor Lavington. Scala Yard (Architect: DLA Design Group) received a commendation in the Small Housing development category.

Anglian Brickwork Ltd, who were the winners of the Specialist Brickwork Contractor award, used Ibstock Bricks in one of their winning projects at the David Attenborough Building (Architect: Nicholas Hare).

Darren Bowkett, Operations Director of Ibstock Brick, commented: “Each year the standard of entries for the Brick Awards improves. As the market leading brick manufacturer we are delighted to be associated with the celebration of brick as a modern building material. We would like to congratulate everybody involved with the award-winning projects for their success in showcasing how brick can be used within creative and contemporary architecture. Ibstock Brick is committed to providing products which offer design flexibility for the most innovative building facades.”

Photo caption: Creek Road, which was the winner of the Architect’s Choice Award at the Brick awards, utilised Ibstock Brick’s Funton Old Chelsea Yellow.

For more information please go to www.ibstockbrick.co.uk
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Family-owned cheese factory cheddar a few pounds with the help of Kingspan

Popular Welsh manufacturer, GRH Food Company, has toasted its latest expansion which is set to double its production capacity. Work on the state-of-the-art facility includes the installation of The Kingspan KoolDuct System which provides a lightweight solution for the facility’s ventilation and cooling requirements.

The expansion at the Snowdonia Business Park includes the creation of a Cheese Innovation Centre to test new trends for blends, flavours and high nutrition cheeses for UK and international markets. Overseen by mechanical contractor, DD Cooling Ltd, 800 m2 of the Kingspan KoolDuct System was installed on the Air Handling Units by delivery partners, Holders Sheet Metal Ltd.

Ductwork fabricated from the Kingspan KoolDuct System can help to reduce operational costs as it is capable of reducing air–leakage rates to a fraction of those typical of rectangular sheet metal ductwork, in addition to limiting heat transfer, which will help to maintain a controlled temperature for the cold rooms. The System can also weigh up to 75% less than ductwork constructed from galvanised sheet steel and insulated with mineral fibre. This was key to its specification, as Craig McNaught, Project Manager from Holders Sheet Metal Ltd, explained:

“Air Handling Units have been used to make servicing and cleaning easier but, with the ductwork needing to be installed on a suspended ceiling, weight was an issue. Kingspan KoolDuct was ideal as it could ensure the cool air that passes through the ducts remains unaffected by the heat generated through cheese production, and the ductwork is also much lighter than other options.”

An additional challenge for the project was access to the ductwork. Kingspan KoolDuct is pre-insulated ductwork that allows the installation to be much easier and less time-intensive than lagged ductwork as it can be installed in a single-fix.

Craig McNaught added:

“Due to access issues, the duct needed to be manufactured and assembled in the roof space. Being able to take a selection of hand tools up with the Kingspan KoolDuct meant that the project could be completed on time.”

Ductwork fabricated from The Kingspan KoolDuct System is also well suited to projects targeting high standards in energy efficiency. The system panels have been assigned a highest possible BRE Green Guide Summary Rating of A+. The Kingspan KoolDuct System is also UL Listed as a Class 1 Air Duct, to Standard for Safety UL 181 (Underwriters Laboratories: Factory Made Air Ducts & Air Connectors), when fabricated to a specification clearly defined by UL.

For further information, please contact: Tel: +44 (0) 1544 387 384 email: info@kingspaninsulation.co.uk Website: www.kingspaninsulation.co.uk
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Historic building renovation enjoys sea and sky views thanks to Xtralite

A historic building in the seaside town of Whitley Bay has undergone a radical renovation and development programme restoring it to its former glory.

Spanish City, which was constructed in 1910, has been given a new lease of life as part of a coastal development plan driven by North Tyneside County Council. Its unusual name is reputedly borne from the ‘Toreadors’ concert party who played on a temporary stage in what was then home to Rockliffe Rugby Club between 1904 and 1907. To protect their audience from the inclement North Eastern weather, canvas and wood awnings were built and painted to look like a Spanish Village and the rest, as they say is history.

Fast forward to the 21st century and the £10m investment has seen the restoration of original features along with modern extensions and the wonderful rotunda atop the building has been beautifully brought back to life as a focal point of the project. The ceiling of the central space has been removed from the ground floor to allow visitors to see the iconic dome and the architectural detail.

“We are proud to have been able to supply products to this stunning project which will rejuvenate the heart of this seaside community,” said Jim Lowther sales director Xtralite. “Our rooflights will allow visitors to make the most of the lovely sea views and have integrated seamlessly into the heart of the building with ease, balancing practicality and aesthetics perfectly.”

Xtralite supplied products from its X-Glaze range which incorporated a series of self-supporting 37.5mm double glazed units with dimension of 4.92 metres wide and a slope length of 2.52m pitched at 5° 7 units covering an area of 86.78 sqm.

The Double Glazed Glass units were made up of 10mm thick Guardian SunGuard 70/35 toughened solar control outer pane, 16mm Argon filled cavity with black spacer bar, 11.5mm thick clear heat strengthened laminate with Ionomer interlayer and black boarder to give building users greater comfort. Practically, the units were fitted directly to the builder’s kerb and resulted in a 1.2 W/m²°K Ud value (relating to the glazing units only).

Andrew Coleman, Senior Project Manager at Robertson Construction, main contractors for the project commented; “It was important to flood the building with as much natural light as possible and to capitalise on the lovely sea views afforded from certain aspects of the building. Balancing comfort, aesthetics, building regulations and thermal efficiencies can be tricky but the reputation and reliability of Xtralite products allowed us to fulfil all requirements. Supply was efficient and technical information and support was readily available allowing us to stay on track with our timescales to meet the launch deadline of summer 2018.”

Jim concluded: “This is a prime example of how modern products can be used in historic restoration programmes to great effect sympathetically embracing the fabric of the building but making it fit for its new intended purpose.”

X-Glaze is just one of a range of glazing and rooflight products offered by Xtralite.

Further information can be found by visiting www.xtralite.co.uk or by calling 01670 354 157.
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Make some noise for new acoustic pipework course from REHAU

REHAU has launched a new CPD course for professionals who want to learn more about the specification and installation of acoustic soil and waste pipework solutions.

Fully accredited by CIBSE, the new course introduces best practice in the design and specification of soil and waste pipe systems to ensure quieter installations. Acoustic pipework is particularly important in multioccupancy buildings, such as residential accommodation, care homes and hospitals, where noisy pipework can have a detrimental effect on the building’s users.

The course opens with the fundamentals of acoustics, explaining noise transfer and pollution, before moving on to design considerations and standards. In this section, attendees on the course will find out more about the requirements for acoustic pipework in the Building Regulations, the market expectations for noise pollution in different settings and how acoustic pipes are tested.

The CPD course touches on fire safety considerations and BIM Level 2 before going on to share practical guidance about which pipe materials and joints perform better acoustically and how to achieve more successful installations.

REHAU is well placed to advise course attendees on acoustic pipework installations as the company has been manufacturing acoustic soil and waste pipes for over 20 years and supply it in 37 countries. Earlier this year, REHAU launched its RAUPIANO acoustic pipework solution to the UK market.

Drew Clough from REHAU said: “Since we introduced the RAUPIANO system to the UK, we’ve had a lot of interest from industry professionals who want to know whether it’s right for their projects and how to design and install it. We’ve pulled all that information together in one CIBSE-accredited course to answer those questions and provide the necessary technical information to inform the specification process. It’s absolutely free to attend, and in our opinion, it’s a must for anyone involved in the design and installation of soil and waste pipes, particularly in multi-occupancy buildings.”

REHAU’s acoustic soil and waste pipework CPD course is available at a customer’s premises across the UK and can be booked via the link www.rehau.uk/cpds
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New Protective Adjustable Threshold Eliminates Construction Problem

Yeovil-based Cavity Trays Ltd has developed a ready-to-use solution to eliminate a reoccurring construction problem when building on contaminated land. Originally conceived for Radon gas situations, it is called the Type PAT – Protective Adjustable Threshold.

Where gas barriers are present within the external cavity walls of a building and the door openings interrupt the arrangement, maintaining gas-tight integrity and damp-proofing measures is always difficult. Commonly door openings are at a different level (access requirements) and interrupt the protective arrangement against rising gas.

Using flexible DPC requires support from higher courses and creates a cumbersome arrangement in which achieving a gas and water-tight arrangement that links with threshold and closers is difficult.

The Type PAT eliminates this problem.

The new Protective Adjustable Threshold (Type PAT) from Cavity Trays provides both gas and water protection under and to the sides of every opening and does so in a way that eliminates discontinuity and provides adjustable connection with adjacent barriers.

The Type PAT – Protective Adjustable Threshold – is a three-dimensional DPC unit that is bedded within the external wall opening. Integration between wall barriers and the Type PAT is achieved using the adjustable side connectors that attach to the Type PAT and slide up and down to the requisite level. The cavity face of each connector has a projecting connection profiled to match that of the external wall DPC/barrier profile. Once in position, all lapping sections are lap-sealed and gas-tape bonded. The footprint membrane is integrated in the usual way to maintain gas-resistant integrity.

The side connectors are supplied with different projecting profile options to match the wall barrier profile selected by the designer.

The Type PAT DPC threshold unit is usually supplied in three sections consisting of two corners and an infilling channel base length. These three components overlap so always accommodate the as-built structural opening width. Wider openings of any dimension can be formed by introducing additional lapping channel base lengths across the opening and sealing using gas-grade bonding strip.

The reveal closers (compatible caviclosers available) descend into the cavity-projecting sides of the Type PAT, terminating within its channel base in which are located flexible drainage conduits*.

(This channel base can additionally accommodate an optional insulating strip if thermal enhancement is sought under the sill.

*Part C, page 37. 5.32 describes closers having fins These provide capillary breaks in the reveal closing arrangement and allow water to gravitate between fins for discharge at the closer base. The flexible conduit provides the water escape route, without compromising Type PAT continuous gas protection across the base of the opening.

For further information visit www.cavitytrays.com or tel: 01935 474769.
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Cembrit gets a first at the University of Northampton

Cembrit is delighted that its Moorland fibre cement slates have been specified and installed at the new campus development at the University of Northampton. Situated on the River Nene the new Waterside Campus features a mixture of academic buildings and student accommodation. Specified by Stride Treglown and installed by Russell Roofing, the Moorland slates dressed edge provides an aesthetically pleasing natural looking roof covering, for the new prestigious student accommodation blocks at the university, at a lower installed cost than natural slate.

Located on a former brownfield site, the development responds to the industrial heritage of the site in a contemporary way. The student residences are located immediately adjacent to the new academic accommodation and incorporate a variety of additional facilities including a health centre, multi-faith chaplaincy, convenience store, bank, hotel school and launderette. The additional facilities within the development take a holistic approach to urban regeneration as well as giving the university an opportunity to consolidate its campus estate into one location. The new student residences, which are being developed in two phases, consist of a mixture of shared townhouse and cluster flat accommodation with the Moorland slates being installed on pitched roof areas including the main roof and mansard sections.

Keystone Roofing have supplied Russell Roofing with over 47,000m² Moorland slates so far and Frazer Simpson, Director of Russell Roofing is delighted with how the project is taking shape: “The development is a great looking project and looks particularly impressive with its waterfront location. The Moorland slates fit in perfectly with the surrounding and with their dressed edge and lightweight construction add a classy, but easy to install quality to the project. We’ve used them before and definitely will do again.”

Cembrit Moorland slates are designed with a dressed edge and smooth surface, they are light weight, pre holed and easy to cut with hand tools making them a cost effective product an added benefit for the University of Northampton. Moorland slates random, dressed edge creates a roof slope with a natural appearance, they are fully coated with a high quality, semi-matt acrylic pigmented finish which ensures the natural appearance is visible from street level.

For further information visit www.cembrit.co.uk, email sales@cembrit.co.uk or tel: +44 (0) 208 320 1184.
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Aico Alarm Interface used in high risk fire safety systems

Fire safety start-up company Lite4Life has adopted Aico’s unique Ei414 Fire / Carbon Monoxide (CO) Alarm Interface into its Multiwatch tower block fire safety system and AlightforLife Directional Way Finder Safety Light. The Ei414 is being used to alert these systems in the event of an activation from Aico Fire and CO Alarms. In the case of AlightforLife it activates LEDS pointing to the nearest exit.

Andy Cunningham, Managing Director of Lite4Life, selected the Ei414 based on its ability and Aico’s reputation in the marketplace: “It is so much more user friendly than anything else on the market. We are finding that using the Ei414 to send messages and signals to report on alarm status at the earliest opportunity gives us valuable minutes in the protection of people and property from a potential devastating fire. The recent Hackitt report for High Risk Residential Buildings (HRRB), recommends that high risk buildings are to be managed and our product, using the Ei414, can provide the solution for many of the points identified by Dame Judith Hackitt. We at Lite4life, feel it archaic to rely on a member of the public to notify the fire rescue services, often after the fire has been alight for some time. A fundamental change must be highlighted in the way we can approach fire protection in high rise residential buildings and Aico go a long way in supporting our vision.

“All of our future projects, including those addressing the HRRB standard, will be using Aico products. We are aligning ourselves with tried and tested companies to deliver demonstrable cost saving with innovation. Working with Aico has been fantastic; with our relationship with Andy Speake [National Technical Manager] and the Regional Specification Managers, why would we use anyone else?”

The Ei414 Fire/CO Alarm Interface from Aico provides a dedicated connection between Aico Smoke and CO Alarms and third party safety systems. It is frequently used to connect alarms to Telecare/Warden Call systems, Sprinkler systems and BS5839 Part 1 panel based Fire Alarm systems. The connection can be made wirelessly with Aico’s award winning RadioLINK Radio Frequency (RF) technology or hard wired directly between the two devices.

The Ei414 can be powered directly from the mains or from a 12-24V DC supply and has built-in tamper-proof rechargeable Lithium Cells which will power the device in the event of any mains failure. Reliable, easy to install and use, it features a ‘test’ setting to test the entire system including a signal being transmitted to the third party system.

Aico, an Ei company, is the market leader in residential fire and CO protection in the UK. All alarms are designed and built in Ireland specifically to meet the UK standards and regulations. For more information please visit www.aico.co.uk or contact Aico on 01691 664100 or email enquiries@aico.co.uk.
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