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A modular approach

Modular building projects are on the increase, reports Giacomini UK, and most notably in the education sector.

Giacomini UK, one of the UK’s leading underfloor heating providers, has recently noticed an influx of modular projects with its three most notable all being for primary schools or nurseries.

Modular underfloor heating systems consist of pre-built modules, which are installed in transportable sections of various sizes. The sections are created in a controlled factory environment and are then delivered to site and craned into position to simply be connected together.

This innovative system results in projects being completed punctually and quickly as, by using the modules, efficiency and installation speed are maximised with limited disruption on site. However, most importantly for the schools involved, the biggest benefit of using modular underfloor heating is that it is very cost efficient and helps keep the project comfortably within budget and effortlessly within the tight timeframes such as school holidays.

Giacomini was selected by Hull based Servaccomm for the projects which saw the company supplying the underfloor heating materials for the plated modular systems, as well as factory pressure pre-testing the systems and fitting the manifolds on site.

The first project was at Prae Wood primary school in St Albans where the UFH was installed on the ground and first floors as part of the school’s £2 million expansion. This was followed by two further school projects, which saw Giacomini UK and Servaccomm install modular systems within a state-of-the-art nursery and primary school in Milton Keynes.

Matt Lowe, managing director of Giacomini UK, commented: “Underfloor heating is proving to be increasingly popular within schools due to its safety benefits as well as being cost efficient. Further to this, by working with Servaccomm’s modular builds we can ensure minimal disruption is caused to the customer, due to the majority of the construction and installation taking place in the factory with only the final connection taking place on site.”

For more information please visit www.giacomini.co.uk.
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“Construction industry showing encouraging signs of change to offsite methods”

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Speaking at Explore Offsite Futures at Birmingham’s NEC last week (24th November 2016), Fusion’s head of business development, Robert Clark spoke about the past, present and future opportunities for offsite manufacturing, saying he was starting to see encouraging signs of adoption by the construction industry.

As a designer and manufacturer of light gauge steel frames used by some of the UK’s most significant developers, Fusion is at the forefront of driving education and awareness of how offsite manufacturing methods hold the key to the future of construction in this country.

In his presentation to an audience of around 180 delegates from across all disciplines within the construction industry, Robert outlined the history of Fusion. He spoke about its experience in designing and building frames for low rise housing units through to high rise apartment blocks, and how its strategic view now is to focus on low rise, volume house building to help reduce the UK’s desperate shortage.

Robert recounted stories dating back 15 years when some of Fusion’s first projects were completed and little was really know or understood about the possibilities for offsite manufactured steel frames. Looking at the present, he referred to the widely-read Farmer Review: ‘Modernise or Die’, facing the truth about the drastic shortage of housing in the UK and the devastating decline of skilled labour in the construction industry.

Robert said: “The construction industry – or house building in particular, is faced with a dire situation. We’re still trying to make traditional building methods work but as Mark Farmer said in his review, radical steps need to be taken if we are to avoid an ‘inexorable decline’.”

With offsite recommended as one of a number of solutions, Robert explained projects which were currently underway using Fusion’s intelligent end to end service of design and manufacture and build – but pointed out that up until now, projects have largely been one off developments.

Robert continued: “A change in mindset needs to happen and I’m pleased to say it’s starting to. If we’re to make a serious impact on the construction process and housing shortage in the UK, offsite manufacturing needs to work in collaboration and as part of a developer’s integrated supply chain.”

Robert explained how Fusion was starting to see encouraging signs of change and an adoption of offsite manufacturing methods, from school building projects to a trial programme with the UK’s largest house builder. He also alluded to a branding idea called ‘4LP Homes’ or ‘four little pigs’, the fourth pig having his home made out of steel – strong, warm and built in a factory.

Robert was one of 16 speakers at today’s Explore Offsite Futures event – run as part of series of one day conference and exhibitions creating a platform for construction clients and their professional advisers to explore the latest offsite construction solutions, providing a dynamic and interactive learning experience for all visitors.

For further information visit www.fusionbuild.com and www.exploreoffsite.co.uk.
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Explore Offsite Zone to be showcased at Ecobuild

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  • Offsite construction expert voice added to the schedule for Ecobuild 2017
  • A series of masterclass seminars will explore the role offsite construction technology will play in tackling the housing crisis and the efficient delivery of infrastructure projects

Ecobuild has announced that it will be partnering with Cogent Consulting, leading experts in offsite construction and Radar Communications, the organisers of the Explore Offsite series of events and conferences to deliver a focused exhibition zone and series of offsite masterclasses for the 2017 edition of the show.

Explore Offsite at Ecobuild, in partnership with Offsite Magazine and the Offsite Hub, will be a dedicated show feature focused on supporting attendees in learning more about the exciting opportunities offered by offsite technology in the future of construction, through a three-day seminar programme and exhibition. By focusing on technology and product innovation, the extensive calendar of masterclasses and demonstrations will highlight the benefits of offsite technology across the built environment – from housebuilding to infrastructure.

The seminars will take place alongside exhibitions showcasing each of the six main types of offsite construction – modular volumetric; steel; timber; concrete; roofing and MEP/pods.

Offsite construction is contributing to resource efficiency, the circular economy and diversifying the skill set in the built environment, all of which will be evidenced by a range of leading exhibitors representing the sector at Ecobuild 2017.

Explore Offsite at Ecobuild comes at a time when the Government is acknowledging the substantial potential of offsite construction. A white paper to be released this month, announced by housing minister Gavin Barwell MP, will look at ways to utilise offsite technology to build 100,000 modular homes over the course of this Parliament2, in a bid to tackle the housing shortage.

With the UK also facing a potential shortage of primary school places, Explore Offsite at Ecobuild will feature the latest innovations in the use of offsite construction to create additional classrooms or add storeys to existing school buildings1.

Visitors will be able to see how extensions can be manufactured away from the building and craned into place in a matter of weeks – offering a sustainable choice by reducing vehicle journeys and increasing efficiency.

Martin Hurn, brand director at Ecobuild, said: “Offsite is clearly the future of construction technology, and it’s happening now. Offsite presents many opportunities for the private and public sectors. Currently some projects can deliver a modular home in 48 hours, which has huge implications for the industry. Our audience wants the latest technologies, systems and processes, and Ecobuild can find no better partners than Cogent Consulting and Radar Communications to bring this to the stage in 2017.”

Darren Richards, Managing Director of Cogent Consulting, said: “Increasingly the construction industry is turning its attention to the substantial benefits offsite technology can offer. In order to make the most of what is possible, clients, contractors and industry at large must have up to date knowledge of what offsite technology suppliers can offer.”

Ecobuild wants to hear from companies who are championing innovation in sustainable construction, design and energy in the built environment. If you are interested in helping shape the 2017 show, find out more at www.ecobuild.co.uk.
Learn more about Explore Offsite at Ecobuild at  www.ecobuild.co.uk/exploreoffsite
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100,000 modular homes planned to alleviate housing crisis

According to a government white paper which will be published next month, the Government intends to utilise offsite technologies and build around 100,000 modular homes across Britain by 2020.

The report includes measures that will make lending to offsite home builders more attractive to banks.

The rapid delivery of recent offsite projects (sometimes as quickly as 48 hours for some modular homes) has made the construction method a very interesting and viable option for ministers in tackling the shortage of housing in the UK and meet targets.

In an article in The Telegraph, a government spokesperson said “The first and most obvious advantage is speeding up the building of housing. There is pretty good evidence that if you did it at scale it is cheaper.”

The Communities Department hope the measures will lead to 100,000 off-site manufactured home being built over this parliament.

Housing minister, Gavin Barwell commented: “Offsite construction could provide a huge opportunity to increase housing supply and we want to see more innovation like this emulated across the housebuilding sector.”

The Government have initially identified two key areas where support must be given, the first of which is to provide direct funding to construction firms in order to help them deliver new prefabs. Secondly, they want to encourage lenders to make more money available by showing them that the technology is low risk and lucrative.

Whilst compiling their research, Housing Minister Gavin Barwell and communities secretary Sajid Javid visited West Midlands based housing association ‘Accord Group’, who have stated that they can create a three-bedroom house at their factory in just 24 hours. They also visited London firm ‘Pocket’, who specialise in building affordable flats for first-time buyers.

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“Modernise or die”, warns Government-commissioned review

Britain’s construction industry faces “inexorable decline” unless radical steps are taken to address its longstanding problems, according to an independent review commissioned by two Government departments.

The Farmer Review of the UK Construction Labour Model highlights construction’s dysfunctional training model, its lack of innovation and collaboration as well as it’s non-existent research and development (R&D) culture. Low productivity continues to hamper the sector, while recent high levels of cost inflation, driven by a shortage of workers, has stalled numerous housing schemes as they have become too expensive to build.

Led by Mark Farmer, chief executive of Cast, a real estate and construction consultancy, the hard-hitting report says we need to better align the needs of construction firms and the businesses who hire them.

“If you buy a new car, you expect it to have been built in a factory to exacting standards, to be delivered on time, to an agreed price and to a predetermined quality” said Farmer. “This needs to happen more in construction, so that the investors, developers or building owners hiring construction firms increasingly dictate the use of modern methods of delivery and invest appropriately in the skills agenda to grow this part of the industry. There are more similarities between manufacturing and construction than many people are led to believe and this perception needs to change, starting in the housing market.”

One recommendation set out for the medium term is a “carrier bag charge” style behavioural deterrent scheme. This would levy a tax on businesses who buy construction work in a way that doesn’t support industry innovation or skills development. Clients could face paying a suggested levy equal to 0.5 percent of a scheme’s construction cost but would have the ability to avoid paying this tax completely by commissioning construction in a more responsible way.

Farmer, a 25-year veteran of the industry, and former partner at EC Harris, said the industry needs to be far more joined-up with its clients in how it approaches R&D and skills. He also wants ministers to directly intervene in certain areas to ensure many of the issues identified are rectified.

Commissioned by the Department for Communities and Local Government and Department for Business, Energy and Industrial Strategy, Farmer has made 10 recommendations which include:

  • Using the residential development sector as a pilot programme to drive forward the large scale use of pre-manufactured construction, for example, through off-site built or modular housing.
  • A wholesale reform of the current Construction Industry Training Board (CITB) and its related levy system, including a new mandate to properly fund and drive forward both appropriate skills development and innovation to suit a modern progressive industry.
  • Government to use its education, fiscal, housing and planning policy measures to initiate change and create the right conditions that will support the construction sector’s modernisation.

With more people leaving the industry each year than joining, the construction workforce is shrinking, placing increasingly severe constraints on its capacity to build housing and infrastructure. Reliance on a fractured supply chain and self-employment also means there is little incentive for contractors to invest in long term training for the labour force.

The situation is exacerbated by the fact that many school leavers and graduates don’t view construction as an attractive career choice. A YouGov poll earlier this year found that two-thirds of Britons wouldn’t consider a career in construction. If Brexit results in reduced migrant labour, the situation could be made even worse.

Crucially, it hasn’t raised its productivity in decades so urgently needs to explore ways to make the work less labour intensive, such as through offsite construction. This, in turn, could make a career in the sector more attractive for young people by moving the work from building sites to digitally enabled working in factories.

Industry Minister Jesse Norman commented “This Government is determined to support more housebuilding, more quickly and in the places people want to live. Given the launch of the £3 billion Home Building Fund, Mark Farmer’s important review in this vital sector is very timely. It makes a strong case for change in the industry, identifies areas where it needs to improve, and sets out areas for action. We will now carefully consider his recommendations.”

Paul Stanworth, Managing Director of Legal & General Capital added “This review sets out a clear way for the construction sector to reinvent itself in order to meet the ever-growing demand for homes and infrastructure. With such a chronic shortage of homes in the UK, we see rapid evolution as a “must have” for the industry, not just a “nice to have”. Having identified such a requirement, Legal & General is helping to address this problem by investing in a modern factory to produce homes using manufacturing processes seen in the production of cars and other consumer goods. This construction method is safe, clean, and fast, providing a high level of consistency and durability. We sincerely hope that Farmer’s review galvanises the entire sector to invest in innovation and secure its future.”

Download the full report here.
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Willmott Dixon unveils modular prison suite concept

Bigger ‘all in one’ premises developed following recent custody suites we’ve built in Newcastle, Sheffield, Birmingham and South Wales.

Willmott Dixon is launching a range of pre-designed custodial facilities that give police forces more options as they look to roll out a new generation of larger custody suites to replace outdated facilities.

Police forces are investing millions in moving to larger custody suites to create better working environments for staff and detainees and provide more efficient use of property that will save millions in running costs each year. This includes Willmott Dixon recently delivering 50+ cell custody suites for police forces in South Yorkshire, South Wales, Newcastle and West Midlands.
In the case of South Yorkshire, the police force expects its new purpose-built 50 cell centre in Sheffield to replace inefficient custody suites in Rotherham and Sheffield and save £1.2 million a year in running costs. Likewise, West Midlands Police expects its new 60 cell Central Custody Suite in Perry Bar to save the force £1.3 million per year.

To support the move to a new generation of modern, energy efficient custody suites, Willmott Dixon has developed a standardised offering called CODE with a range of pre-designed custody suites to suit different police force budgets and requirements. CODE models have been designed in partnership with NORR Architects, our supply chain partners, the Home Office and over 20 different police forces to tackle issues such as minimising the risk of detainee injury, increasing security of evidence and providing a better working environment that is more efficient and sustainable.

CODE has three models; Alpha providing up to 28 cells, Bravo up to 36 cells and Charlie for forces that require more than 36 cells; police forces can also completely customise their suite to ensure it meets their individual needs. All CODE projects are delivered with a fixed cost, timescale, quality and minimum risk; they also provide significant social value and community engagement commitments, a defining factor of Willmott Dixon projects.

It follows the success of the Sunesis standardised school concept developed with Scape Group that has seen over 25 primary schools built in three years across the country providing over 9,000 new places for a fixed cost and time scale.

CODE custody suites can also be procured through the Scape National Major Works framework, an OJEU-compliant procurement route that allows customers to engage directly with Willmott Dixon and reduce the time and resources spent on a lengthy tender process.

Anthony Dillon, managing director at Willmott Dixon Construction: “CODE has been developed with expert partners NORR architects, the UKs most experienced custody design practice and also in conjunction with the Home Office to produce standardised designs we are truly proud of. There are many pressures facing our police forces today and we are delighted to be able to play our part in supporting them by providing the most advanced modern facilities that are also economically efficient.”

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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.
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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.
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Innovative offsite designs that shatter all perceptions

It is now widely accepted within the industry that off-site construction can provide high quality, fast and disruption free buildings that rival more traditional construction. But can they provide design led innovative buildings or is this still an area of compromise when you decide to build off site?

When asked, Rachel Davis, Business Development Director, said ‘With Premier Modular the answer is NO, we never compromise. What we bring to the market are design solutions that push past the normal modular limitations. Sloped roofs that can create ceilings heights over 5m and incorporate north lights to bring daylight and ventilation to areas that would otherwise be inaccessible. Floor to ceiling windows and curtain walling to give a light and airy feel and roof top ball courts and play areas to make the best use of tight sites in city environments’.

Each project is solution focused, Premier Modular Ltd takes the opportunity to ‘think outside the box’ and move forwards with each building they produce, every endeavour breeds innovation.

Inner City Constraints

Premier Modular Ltd recently delivered a scheme in Westminster, London, acting as the main contractor. Premier worked with the client design team to ensure that 75% of the building could be built offsite due to the restricted inner city residential site.

The project was a four storey community scheme, incorporating a nursery, staggered to create roof top play areas with laser cut steel panel/ glass balustrades and green roof outers. The laser cut panels were also replicated as Juliet balconies and external stair cladding. Another design feature was the double height sports hall with large floor level and high level windows. The building also had many sustainability features built in to achieve London Plan and BREEAM Excellent.

There were several key areas as well as the design which contributed to this complex project, removal of asbestos during the demolition phase, piled foundations working over the London Underground system and road closures. Premier’s skilled project management team worked with the local police, client bodies and the local communities to minimise disruption to the local residents.

Unique Places to Learn

Premier Modular Ltd working as a specialist subcontractor to Conlon Construction are currently building a new Free School in Manchester, New Islington School. This will be a new home for 420 children and is due to open for the September term 2016.

Premier worked with their architectural partners Vaughan Architecture & Design to create this visually stunning building with angular external walls, a feature entrance with oversailing roof, picture windows, a lightwell running the full length of the building bringing light from roof to ground floor and an external cladding panel giving the school a very modern finish. The building also includes a roof-top teaching space to maximise the space available on site and an external play area linked to the building. Sustainable and wildlife features were also included such as PV panels, bird and bat boxes and a Redstart habitat was created on the roof.

The New Islington School values are Creative, Innovative & Unique. These fit well with Premier’s own values and have certainly been captured in the new school building.

Rachel Davis, Business Development Director at Premier Modular said ‘The client is at the centre of everything we do, we feel that having the right environment around us as we work, learn and live can inspire us, support us and motivate us therefore making our schools the best place to learn is essential’

‘Giving children and teachers a quality environment with all the spaces required to teach and learn makes them feel valued and builds confidence. An inspired, confident and motivated culture breeds; Therefore creating inspiring buildings which teachers, students and the surrounding community can be proud of will take our education forwards maintaining it as one of the best in the world’

So at a time where an increased rate of build is required, budgets have been cut and there is a squeeze on available space, Premier Modular has firmly proved that design doesn’t have to take a back seat.

For more information please visit www.premiermodular.co.uk.
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Securikey works the room with its new Modulprim features

Leading physical security specialist, Securikey, has made innovative modifications to its range of Modulprim security rooms. The Modulprim is a bespoke modular vault solution for both new builds and existing buildings and is a convenient and cost effective method of adding a high security strong-room to a building. The Modulprim offers a complete storage facility for money, documents and pharmaceuticals and is adaptable to most building specifications, even those with limited space or those located on upper floors. This impressive level of adaptability has now been increased further with the introduction of new lighter-weight materials to offer even further convenience and more storage space.

Securikey’s Modulprim components have now been adapted, using new materials, to provide further options, ease of installation and accessible space. New light-weight panels combined with reduced steel work decrease the weight of the original Modulprim by up to 25%. In addition, the new method allows for unsupported space of up to 12 metres with no internal pillars, compared to 7.4 metres on the original, providing the customer with a much greater amount of useable space along with increased flexibility in layout.

Pre-fabricated off-site to precisely fit a detailed floor plan drawn up by Securikey, the Modulprim components are welded together from smaller panels allowing installation in difficult to reach locations which means that it can be easily modified at a future date and it is also possible to disassemble the vault and transfer it to another location.

The Modulprim can be installed on any floor capable of taking the minimum load capacity, the scope of which has now been widened with the introduction of the new lighter weight components and, although extremely robust, the walls are relatively small in width enabling the Modulprim to be installed in more compact areas without compromising on security.

Consisting of four walls, a floor, celing and vault door as standard, the Modulprim can also be supplied as a five sided solution if desired, as is often a requirement for the pharmaceuticals market. The Modulprim door, which is manufactured from steel and delivers a level of protection that is equal to or higher than the vault room itself, is available in Grades ranging from 0-9 depending on the level of security required. All vault elements are subjected to exhaustive tests to meet European security standard EN1143-1, ensuring European wide approval and, in addition, each product is branded with the appropriate badge as proof of certification – the Modluprim also has the approval of SBD (Secured By Design), the official UK Police flagship initiative combining the principles of ‘designing out crime’ with physical security.

As testimony to Securikey’s reputation for efficient and user-friendly products, the unique construction of the Modulprim also allows for the space above the Modulprim to be used for storage of up to 500kg per square meter if required, meaning that not an inch of space is wasted.

For more information about Securikey’s Modulprim or to download the latest strong-room catalogue, visit www.securikey.co.uk/vaults-and-safe-deposit or call 01252 311 888.

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