new build
Planning consultant: McCutcheon Mulcahy Facade specialist: Billings Design Associates Fire consultant: Cantwell, Keogh & Associates Landscape consultant: Forestbird Design
Ground works: PJ Hegarty Envelope contractor: Alucraft Structural steel: Cronin Buckley Roofing contractor: MultiRoofing Systems
PROJECT OVERVIEW: Building type: steel-frame distillery production building. 960 sq m footprint, 21.5m high (to apex of roof-lights). The main access from the garden is via a bridge to an intermediate level. Access is restricted due to the nature of the process. The retention of existing hedgerows and features has retained the garden setting for this unique building. Location: Midleton, Co Cork Completion date: first base spirit produced in march 2013, practical completion achieved in August 2013 Cost: €3.6m (€3,750 per square metre) Passive house certification: not sought Airtightness: A full air leakage test has not been carried out but the building was designed to achieve 1 ACH. The nature of the process and concerns regarding alcohol vapours and their volatile nature was complimentary to ensuring that the overall envelope retained airtight and vapour control throughout.
Glazing consultants: Nazeing Glassworks Sprinkler system: Writech Solar wall & cladding: Tegral Solar wall design: CA Group Isokorb thermal breaks: Contech Accessories Basalt wall ties: Longs Aluminium louvres & brise soleil: QEF Ltd Aluminium doors: AMS Roof membrane: Soprema Ireland Insulation: Kingspan/Rockwool
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BER: Not required Thermal bridging: In order to limit thermal bridging a number of methods were adopted. 1. The wall construction generally is a ‘built up wall system which is fitted with an external boarding material – (Duripanel) fitted to 95mm crossrails packed with Rockwool batts. Cross rails are fitted to 175mm vertical rails packed with Rockwool batts. Internally a boarding material – (Hydropanel) is fitted to the vertical rails – joints are filled and sealed to be airtight. This boarding acts as the vapour control and airtight layer. The boarding is faced internally with a self-finished lightweight trapezoidal liner sheet. Externally there are a number of differing finishes. 2. There is an overhang roof element which is insulated to top, leading edge and underside. The structural elements to the primary steel are isolated from the interior environment by Isokorb units. 3. Cavity based masonry construction to the lower ground plinth makes use of high performance ‘basalt’ wall ties to limit thermal bridging. 4. Underside of slabs insulated and the face of foundations are insulated to the underside of the built up wall construction to maintain a complete thermal envelope. Ground floor: Resin flooring, on 300mm concrete slab (power float finish), on DPM, on 150mm Kingspan Styrozone N300R. U-value: 0.15 W/m2K Walls: The wall systems are of built up metal stud/counter stud fully insulated systems with cementituous boards of differing vapour permeability and densities to suit their location. They are generally lined with an internal profiled metal liner. An external rainscreen of fibre cement boards or profiled metal sheeting completed the construction. Rain-screen walls: 8mm Tegral Natura Pro rainscreen cladding (N251 Anthracite) on 40mm Tegral vertical rails, on Tyvek UV façade breather membrane, on 12mm Tegral Duripanel, on 90mm + 145mm sheeting rails full filled with Rockwool Flexi insulation, on12mm Tegral Hydropanel taped & sealed to form vapour check, on 33mm Tegral C33 liner sheets. U-value: 0.16 Roof: mechanically fixed Flagon SR membrane, on 140mm Kingspan Thermaroof TR26, on 1mm Sorprema vapour control Layer, on Rockwool (trapezoidal infill pieces to troughs – nominal 60mm), on profiled metal deck – (Tegral Building Products) – thickness 1.0mm (profile 50mm deep), metal liner sheet (1mm) to perimeter. U-value: 0.15. Glazing: double-glazed low-iron white glass curtain wall system. U-value: 1.6 Heating system: There is no traditional heating system provided in this facility. The building houses presently 3 of the 6 copper pot stills. These large stills, radiate significant heat during the process which is removed using the stack effect cooling. Ventilation: passive stack ventilation system.
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