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Going retro: A shrewd solution to the UK’s housing crisis

Home is a vitally important place for everyone. So it is a sad state of affairs to think that at the moment more than 6 million people in the UK will never be able to buy their own home. And with a massive 1.2 million people currently hanging around on housing waiting lists, something must be done.

The UK’s housing crisis is a stark, cold reality for many Britons who simply cannot afford to buy their own home. Since 1996 real house prices have increased by a whopping 151%, while real earnings have only gone up by a quarter of that figure, according to the Redfern Review. And as a result of unaffordable housing, rising prices and sheer lack of adequate accommodation, many families are finding themselves placed in temporary lodging.

So what can be done?

Addressed in the last Autumn Statement, the government plans to invest £3.7bn into building a further 140,000 homes by 2020, in order to ease the housing issue.

However, this is a tall order to achieve within the space of four short years. So how is the government planning to tackle this and meet its promise?

A blast from the past

In order to build the huge quantity of homes targeted by the close of the decade and at the budget set aside, ministers plan to roll out a new wave of prefabs.

As the first prefabs were the solution to the UK’s housing shortage following the devastation of war in the 1940s, a second wave could be the solution to our current crisis. With over 100,000 prefabricated homes planned across the country, it looks like construction is set to go retro.

Unfortunately, prefabricated housing carries negative connotations for some, who associate it with cheap, temporary and ugly. However, modern modular design has developed considerably over the past 70 years and today’s prefab homes are high quality, contemporary and built to last. Prefabs can be posh.

Modern modular buildings have many other enviable benefits over a traditional brick and block build, such as being more energy efficient, eco-friendly and affordable.

Faster construction, reduced cost

With the cost of construction having dramatically increased over the last five years, the building of brick and block homes carries ever increasing expenses. However, as prefabricated buildings are constructed off-site, costs can be more accurately predicted.

A prefabricated house could cost as much as 40% less than the same building built of brick.

Modular homes are also considerably quicker to construct. An off-site build is not only more cost-effective, but much more efficient. A prefabricated building is less susceptible to potential delays, due to bad weather or shortage of labour, and has more chance of meeting deadlines.

Once manufactured, a modular home can be erected on-site in just 24 hours.

And it is the speed from design to completion that is crucial; it is this that will save the government both time and money.

Cost savings are key

But it’s not only the government who needs to make time and cost savings in order to meet tight deadlines and stick to budgets. It is vital for all businesses and organisations, no matter their size, to maintain a healthy bottom line. And finding ways to save time and money in all areas will build a better, stronger business.

So how can your company be more efficient and cost-effective?

There are many things you can do to become more efficient as a business and still make savings. One only needs to think outside the box. For example, by having a tracking system fitted in your company vehicles you will not only reduce your insurance premium and help to deter theft, but you will save money on your fuel bills and reduce repair costs too. With 24-hour GPS monitoring and a system such as Phantom Insight, you can make sure your drivers do not waste fuel or employ bad driving habits that will cause excess wear and tear on parts.

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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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It’s not what you build, it’s how you build it

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By Graham Cleland, general manager, NG Bailey’s Offsite Manufacture division

Graham-Cleland-webThe current UK automotive sector is often cited as one of the best examples that shows how offsite manufacture can positively boost productivity and overall corporate performance. Historically, the construction sector has had many parallels with the automotive industry but these major investments have transformed the automotive sector into an exemplar.

The first wave of these automotive investments took place at Nissan’s Sunderland plant in 1986 which saw the introduction of Japanese manufacturing approaches including offsite production. Some of the impressive results from this investment have seen car production go from 5,000 per year initially to 10,000 per day which represents over a 100 fold increase in a single generation.

This and subsequent investments from other Japanese companies; changed the landscape of British car manufacturing forever by streamlining the production process and introducing more efficient ways of working  including offsite manufacture and assembly.

The construction sector has always had clear aspirations to use offsite manufacture to improve productivity, health and safety and resource efficiency.  In 2013, the Government’s Construction 2025 report established a series of clear targets for industry to achieve including:

  • Lowering costs by 33%
  • Speeding up delivery time by 50%

To achieve these ambitious targets by 2025, offsite manufacturing will need to play a key role in this.
The Construction Leadership Council was set up on the back of the Construction 2025 report to focus on the delivery of the joint industry and Government commitments. Many of the UK’s leading contractors are members of the Council as it oversees the delivery of the Action Plan and the strategic priorities.

Change comes from the top

To achieve the ambitious targets set out in Construction 2025, there will need to be a shift in how the leadership of many of the UK’s leading contractors view offsite construction.  Having a health & safety culture and incorporating sustainability into projects is now the norm – and there now needs to be a seismic shift to offsite working becoming a similar norm.

As natural and physical resources become increasingly scarce, leaders who are able to understand and embrace how offsite manufacture can be factored into their day-to-day business models; will be the ones who are able to secure competitive advantage.

Move from what to how

Major contractors tend to focus on what buildings they have delivered as opposed to how they have delivered them. By making a subtle change in their mindset, to focus on the ‘how’, there is a huge opportunity to start thinking, and more importantly embedding offsite into every viable solution.

Early engagement between contractors and the wider supply chain should become the norm where everyone comes together to think more about the ‘how’ at the start of projects. By committing to spend more time on the ‘how’; alternative construction methods can be explored and then incorporated into the design and build process.

The change in mindset to make offsite construction really work would require more commitment from clients and developers as it commonly requires the design to be tied down at a much earlier stage, reducing flexibility, and suppliers to be paid much earlier in the cash flow.

The focus is still on what is being built and, as such, the same approach – using traditional construction methods – becomes the default position.

As a general rule it matters not which annual or sustainability report you choose to read, there is plenty of narrative highlighting where major contractors have been active and what they have been building.

We frequently see information about the projects completed, linking schemes to health and safety targets, financial results, environmental results and achievements, but very little information on how such projects were built, the methods of construction and how these have helped contribute to targets.

If this focus were to change, then I believe we could see a considerable change in the methods of construction being used.

GE4C5548-webInvesting for growth

Major contractors still have a fantastic opportunity to make major gains in productivity by investing for growth through the development and implementation of offsite techniques into their business and site operations. The gains made by the automotive sector are something that could be replicated by the UK’s major contractors but it will take vision, leadership and change to drive a revolution in terms of how we deliver projects.

To hit the ambitious targets in construction, the pace of investment in offsite manufacture will need to significantly increase. Also, the way in which offsite is incorporated into construction methodologies on site will also need to be revisited in order to make sure that the maximum time and efficiency savings are secured.

Moving from site to factory

Construction sites by their very nature feature many unknowns. By shifting many elements of the build to offsite manufacture, we are able to produce many of the projects build components under strict factory conditions. As a result of this, the quality of the build improves as each stage of production is closely monitored. By moving the bulk of the work to a factory, less operatives will be required on site and their role will mainly cover installation and assembly so productivity improves. There are also major health and safety benefits from moving the bulk of the difficult work to factory conditions.

ROI – proving the value.GE4C5334-web

At Birmingham New Street Station our modular service ‘spine’ was built offsite then installed in just 15 days, saving over 10,000 working hours and reducing carbon emissions by 57%.

This is just one of many great examples where offsite manufacture has saved time, improved quality and led to better health and safety performance. As an industry, we should be sharing what we are doing and making sure that we measure and demonstrate the tangible results that can be achieved through the use of offsite manufacturing. There is a major education process needed so that the industry as a whole is aware of what can be achieved with a little forward planning and knowledge of what really is possible.

As the UK construction market becomes increasingly global, international competitors who focus on the ‘how’ are becoming the norm. There are many new contractors entering the market that aren’t ingrained in the traditional approach to construction. Many of these new entrants are from the Far East and are bringing a wealth of new approaches to construction delivery. They are approaching the ‘how’ with a factory mentality and focusing on how to bring benefits across the entire construction process. For example, earlier this year in China, a 57-storey skyscraper was completed in three weeks by taking advantage of the reduced construction times made possible by offsite building techniques.

Offsite manufacturing offers contractors a great opportunity to do more for less. Going forward, the most successful contractors will be those that embrace offsite as the norm and develop a strategy that embeds offsite into all aspects of their everyday operations.

There are wealth of solutions and approaches to offsite manufacture and the key for UK contractors will be to not only keep up to date with the latest innovations but more importantly to understand how these innovations can drive their business strategy and their methodologies on site to boost productivity.

I am very lucky in the fact that the company I work for has invested heavily in its offsite capabilities over the last 16 years and, while we have admittedly learnt lessons along the way, that investment and focus on the role offsite plays in projects is now becoming an increasingly dominant factor in the way we approach and more importantly ‘win’ contracts.

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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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WDH – Awake to the benefits of building offsite

Building infrastructure in the UK is under review once again – the recently created National Infrastructure Commission is due to deliver its first report shortly – and better insulation of homes is one of the areas it could address as a part of its wider remit.

Here Mike Stevenson Development Director of offsite fenestration specialist Sidey tells us about their work with WDH in Wakefield through its in-house construction team, Homebuilder, which has already delivered greater thermal efficiency for its residents on a new-build site in the town as just one of the realisable benefits of building offsite.

For WDH there was a desire to deliver truly energy efficient social housing in its most traditional sense – not just properties for rent but genuine social housing delivered for long term residents. Homes with a true social value.

Commenting for WDH, Homebuilder manager Adam Green explained “As one of very few housing associations delivering new properties we are developing homes to be proud of, at a reduced cost with a build quality that is more thermally efficient and will help tenants avoid fuel poverty.”

The 39 dwellings built at Ripley Court are in fact a case study of how to access all the benefits that can be achieved through building offsite.

Mike takes up the story “It was clear that WDH had a real understanding of the value to their residents of building to a high specification and that they understood how building offsite could deliver this for them cost effectively and in line with their time-scales.

“Our involvement with the scheme at Ripley Court came out of long term discussions we had been having with the Homebuilder team about the many benefits to be had from installing high specification windows in the factories of offsite manufacturers with the time and costs savings and the efficiencies in process which installing windows this way would bring.

“Through those ongoing discussions it became obvious that through collaboration with the right supply chain using innovative low risk solutions WDH Homebuilder and Sidey had real synergy and could deliver win:win results. We are both big on collaboration as the driver to maximise technical and supply chain efficiency, so after having completed a more traditional site together we were delighted to get involved with a true offsite scheme.

“WDH’s culture being what it is, they brought other supply chain partners to the table with the same outlook and approach. It transpired that several of these companies had worked together on other schemes for other clients. These companies included the foundation system, structural timber frame manufacturer and the air tightness specialist along with Sidey.

“The absolute key to successfully realising the benefits of building offsite is for partners in the supply chain to have design team involvement and WDH drove this, actively encouraging it from the outset with all parties working with both their in-house design team and external architectural partner.

“The scheme really benefitted from the discussions between ourselves, the architects, the timber frame manufacturer, and the air-tightness solutions supplier. It meant we could design and deliver the optimal specification to WDH without compromise. It was a true offsite development rather than having to convert a previously designed ‘traditional build’ scheme to offsite construction.

“WDH adopted the innovations we suggested, following thorough due diligence, to help realise the overall benefits. This included using our patented KitFix ® bracketing system – which enables windows to be fixed into the apertures of the timber frame panels at the offsite manufacturers premises. The windows are ‘contained’ within the panels in a transport position enabling the panels to be stacked, banded, and transported to site as normal.

“The structures were wind and watertight immediately the panels were erected allowing follow-on trades to commence earlier while the windows being delivered in the panels meant there was reduced overall site traffic, reduced site attendance and reduced Health and Safety risk by removing the traditional impact of site delivery and manual handling of windows.

“Ripley Court is an ‘exemplar’ of what can be achieved when the client/developer drives a collaborative agenda. Others should look to this scheme as the benchmark for how to deliver outstanding technical performance and thermal efficiency coupled with financial and delivery predictability.

“WDH is clearly awake to the benefits of building offsite – others should follow their lead.”

Mike Stevenson is Development Director of offsite fenestration specialists. For more information please visit www.sidey.co.uk.
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Offsite construction: flying factories

Polarwall have recently launched a new Offsite Construction system utilising the concept of Flying Factories.

Large panels (2.5m x up to 3m high) of the Polarwall Insulating Concrete Formwork are assembled either offsite or in a temporary assembly facility which can be allocated near to or at the site.

If there is a crane on site then the panels can be “gang formed” together in lengths of up to 12.5 metres and lifted into location.

Reinforcement can be incorporated into the panel assembly making it ideal for basement construction and retaining walls.

A new internal walling system from Polarwall is also being used. This uses cement fibreboard panels as permanent shuttering and will create a wall which is virtually finished.

A new site has opened in Slough where this revolutionary build method will be showcased to any interested parties.

As part of the Flying Factory concept this project will have its own concrete batching facility on site for filling the assembled Polarwall formwork and for the floors.

The Slough project has 80 apartments, retail space and underground car parking. The contractor M2 Construction is aiming for a fast build construction with a target time of 2 weeks for each floor.

Contractor Andrew Skinner says that “Using the large panels is a very exciting development for us. We have used the Polarwall formwork almost exclusively for the last three years. It is already a very impressive construction material and provides structures that comfortably exceed all Building Regs requirements both in terms of thermal performances and structural strength. Now, by using the large panel assembly we have moved this up a gear and the build speeds are becoming incredibly quick.”

Polarwall Technical Director Alan Wheeler said “The pre-assembled panels are now getting lots of attention from larger contractors who are primarily interested in two things – the use of less-skilled labour in the build and also the high build speeds that can be achieved. The panel system lends itself to larger projects such as light commercial, schools, apartment blocks and multi-unit developments. One contractor is particularly interested in using our products in association with timber frame where we would provide the high strength structure in the lower stories and timber frame would be used on the upper stories.”

The site will be having open days for interested parties who should in the first instance contact Polarwall (01392 823300 www.polarwall.co.uk) to arrange.

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