PERIscope 2023 - 2

UK 2 2023

PERIscope The magazine for the construction industry

In Focus

PERI UP façade access facilitates Treadgold House’s journey to carbon-neutral Treadgold House, London

2

Dear Reader...

Welcome to our winter issue of PERIscope 2023 As I reflect on the last 6 months since joining PERI, I can honestly say it’s been an interesting journey so far. I’m extremely proud of what we’ve accomplished in the second half of the year despite the challenging market conditions across our industry.

to working alongside these individuals and our dedicated workforce for years to come. I can only hope the next generation of talent see PERI as a business to build a long-term career with the right opportunities for growth.

As well as ensuring the safest and fastest ways of working for our customers, protecting our workforce is equally important. A few months back we implemented our upgraded Near Miss Reporting initiative that would enable our business to take more preventative action. Introducing open communication like this gives every employee a channel to report any incidents that may be deemed unsafe, helping to increase safety standards across our business.

We are determined to support talent across the construction supply chain too – that’s why training is high on our agenda. As part of CONSTRUCT, we are helping to improve standards in the industry and have listened to what our customers want.

We have also strived to better our working environment by taking a deeper look at the environment itself. Over the years, we have made changes to our business to reduce our impact on the planet. This year, we invested in Photovoltaic (PV) Cells as part of our Climate Protection strategy. This has involved the installation of solar panels across our three main depots, Brentwood, Glasgow and Rugby.

Unlike oil and coal, solar energy ensures toxic chemicals are not released into the atmosphere or added to greenhouse gas emissions. This puts us on the right track to becoming a greener company.

I’m pleased to report that since installing our PV solar panels, we have produced 330,000kwh of energy across all three depots, which is the equivalent of 155 UK households’ average annual energy consumption.

As an approved-CITB training provider, our accredited courses improve effectiveness and competency on site. Our highly experienced segment teams have created course material and valuable content as part of our in-house training and CPD days. Whether you work in infrastructure, scaffolding or simply want to improve your understanding of temporary works, please get in touch to see how we can support you.

Looking ahead, I want to bring more speed to every part of our organisation. At PERI, we are committed to providing high levels of customer service and within that being able to respond quickly and consistently is key. I am determined to work closely with you to ensure you experience this at every opportunity.

As 2023 comes to an end, I’d like to wish you and your family a restful break over the festive period on behalf of everyone at PERI. We look forward to working with you in the new year.

Enjoy the issue!

We have also been able to reduce our CO2 emissions by 60,000kgs from last year, which is the equivalent of planting 3,600 trees!

This year also marks the 25th anniversary of our Rugby headquarters. Something that we are all so proud of is the number of employees in Rugby that have been with PERI from the start, measuring their careers in decades, not years. I look forward

Ian Hayes PERI UK Managing Director

3

Contents

Responsible PERI UK

ERI UP 6 Pfaçade access facilitates Treadgold House’s journey to carbonneutral

Treadgold House, London

Editor-in-chief Jinal Kansara Editing and graphics Dekany Design Photos PERI UK

In Focus

Editor PERI Ltd. Formwork Scaffolding Engineering Market Harborough Road Clifton upon Dunsmore Rugby CV23 0AN United Kingdom

Print Neil Terry Design & Print Copyright The photos used in this brochure feature certain situations at particular moments on various construction sites.

Additional images, e.g. regarding safety and anchor details, cannot always be considered as conclusive or final. These are subject to the risk assessment carried out by the contractor. © PERI GmbH

8

Preparing for the next big thing in nuclear energy production – Sizewell C Matthew McCarthy reflects on Hinkley Point C and how the project will help shape plans for Sizewell C.

4

10 T he innovative formwork travellers shaping HS2 Copthall Tunnel HS2 Copthall Tunnel, London

12 X L Hoist fulfils the need for

speed on Colindale Gardens Colindale Gardens, London

News 14

5

PERI UP façade access facilitates Treadgold House’s journey to carbon-neutral Treadgold House

Scaffolding installation is complete on Treadgold House, which will enhance the council-owned estate’s carbon-neutral credentials.

Situated in West London, Treadgold House is a 4-storey residential estate which is undergoing refurbishment to provide residents with a more thermally efficient building.

The work involves replacing existing waterproofing coverings, windows and balconies from the building. Two temporary roofs have been installed to provide protection from rain as the current layers are stripped and replaced with energy efficient material.

6

A lthough b oth ro ofs h ave b een c onstruc ted in tub e and fit ting , scaffolding requirements for façade access have been more stringent. The facade access around both buildings is built entirely out of system scaffolding as per the material specification provided by the local council. Next Generation Scaffolding Ltd was tasked with installing both the temporary access and the roofs.

M i t i g a t i n g t h e u s e a n d r i s k of combustible materials was a top priority during the refurbishment. This was especially important given the context of widespread remedial façade works on mid to high-rise buildings across the country. To meet this requirement, the PERI UP scaffolding system was specified for the project due to its all-metal design inclusive of its decks and toeboards.

Danny Barry Contracts Manager I Next Generation Scaffolding Ltd “The ledger-to-ledger connections with spigots are handy when working with multiple returns. With these components, we could use multiple deck sizes to cover the area and erect elevations at different points.”

By integrating different systems in the PERI UP range, design consultant Double Scaffold Design were able to catalyse the assembly process and reduce strain on scaffolders during material handling.

PERI UP Easy decks were used for the main scaffolding platforms due to their light weight, while PERI UP Flex was used on the inside brackets to cover any gaps where the façade steps back.

PERI UP was also designed to blend effortlessly with non-system components on this project, such as tube and fitting for the roof structure and the beam work on the building’s east elevation to enable vehicle access.

Using system scaffolding instead of tube and fitting for the façade access requirements provided a clear walkway for Next Generation Scaffolding on each level, as ledger braces did not need to be installed.

The solution was praised by the scaffolding contractor for its flexibility and wide range of components.

The scaffolding structure is expected to be in place until May 2024. In addition to installing new waterproofing and non - combustible insulation, the temporary access will facilitate solar panel installation and an air source heat pump on the roof.

7

Preparing for the next big thing in nuclear energy production Sizewell C As work on Hinkley Point C continues, Infrastructure Sales Manager at PERI UK, Matt McCarthy reflects on PERI’s involvement throughout its construction and how this project will provide a template for temporary works requirements on the next big thing in nuclear energy production – Sizewell C.

Sizewell C summary

Value engineering

Efficiencies

It is estimated that Sizewell C will generate low carbon electricity for over 6 million houses. With the power plant set out to be a near replica of Hinkley Point C (HPC), its construction will certainly benefit from applying the lessons learnt in the making of Britain’s first nuclear reactor station since the mid-90s.

As the cost of raw materials remains high, value engineering is becoming a fundamental part of procurement and efficiency in the infrastructure segment.

Working with a single supplier for a range of requirements can offer significant benefits, especially when compared to the time taken to raise orders with multiple suppliers. This approach can often simplify an already complex end-to-end process for joint ventures and enables better integration between systems.

Why is early engagement key?

Ver y rarely are the proposals or construction requirements for these projects ever simple. They often require a lot of skilled engineering due to the level of complexity.

It’s important for preconstruction and methods teams to bring temporary works specialists into the conversation early. Engaging with the project team during the pre-design stage presents an opportunity for our team to help improve the buildability of a project and reduce costs. In contrast, a more traditional engagement model limits the ability to make changes collaboratively, making it more difficult and expensive to implement alterations later on.

8

Maximising material utilisation and application is key. For example, our PERI UP scaffolding has been used across infrastructure projects like the A465 Heads of the Valleys scheme and HPC to install and restrain reinforcement whilst giving full access to operatives for concrete pours. The same system can be used throughout the construction sequence with minimal adaptions required.

Again, engaging early on in the process plays a crucial role in value engineering and maximises the benefits for contractors. It enables our sales team and design engineers to collaborate with sub-contractors and main contractors to identify the complete requirements and explore how products can be reused or recycled for multiple purposes.

Rather than focusing on individual product applications, this approach optimises the functionality of the entire solution, while keeping costs low throughout the project lifecycle to achieve the best value for money.

Customer portals like myPERI are ideal for large -scale projects like power plants, as they enable sub-contractors to manage stock levels and provide visibility of every PERI product on site.

All project-related data is accessible on one platform.

We have supplied a range of systems to the HPC site, all of which can work hand in hand with each other using standard components. By blending off-the-shelf components, we can introduce new built-for-purpose systems like our PERI UP or VARIOKIT Traveller to overcome challenges on site.

The integration of our formwork and scaffolding systems is not only more cost-effective than purchasing individual systems from multiple suppliers, but it can also provide a safer and seamless

working environment. This is especially important when considering access in tunnels, bridges, or inside a shaft.

Even on a 175-hectare site like Hinkley Point C, it’s vital to conserve space to ensure worker safety and transport material in and out of the site with ease.

Off-site fabrication can support these types of challenges as formwork can be assembled, stored and delivered just in time for installation on site.

For the reactor on HPC, we fabricated single-sided climbing (SCS) platforms and 11.4m-high formwork shutters for lift cores elsewhere on site. These types of solutions are difficult to build on site without the space, machinery and skilled labour resources.

Tried, tested and improved Our team alone created over 2000 designs for HPC, which can be adapted for Sizewell C. Applying the lessons learnt on HPC will guide the supply chain on how to construct Sizewell efficiently.

We’ve continued to evolve in other areas of the infrastructure sector from HS2 to Thames Tideway Tunnel. On Tideway, our engineers developed the climbing formwork solution we supplied previously at the Blackfriars site to accommo d ate the larger diameter of the shaft at Kirtling Street.

This involved enhancing the hybrid RC S (rail- guided climbing) and SC S (single-sided climbing) climbing system with RCS MA X hydraulics, enabling simultaneous climbing of all platforms and faster cycle times.

Working on multiple sites means that we can refine our solutions and apply learnings on complex infrastructure construction.

For Hinkley Point C , we delivered sc af folding training to over 10 0 workers including apprentices from local colleges. Partnerships like this enable new recruits and contractors to establish a relationship from the outset, whereby the industry’s next generation of construction workers are up to speed with industry standards and best practice.

Likewise, digital animations are increasingly aiding the planning process.

Our Digital Engineering team created an animation for Hinkley Point C’s Adit tunnel to demonstrate the cycling process of our travelling formwork solution. The animation also supported the customer in the implementation phase, where it was used for method statements and as a training resource to show the workforce how it operates.

Minimising the impact of construction The application of sensor technology on sites like HPC can significantly reduce construction time and give us more clarity about the building materials used on site. This means we have greater oppor tunities to construct cleaner and greener, whether that’s pouring concrete efficiently or minimising rework.

Our InSite P ressure S ensor was used on the HOR building on Hinkley Point C to und er st and c o nc rete behaviour under site conditions, the formwork utilisation and opportunity for optimisation when pouring 9m-high walls.

SEE HOW PERI FORMWORK SHAPED THE ADIT TUNNEL Final words The next major nuclear power plant in the UK will introduce exciting opportunities and many challenges for sure. By adopting modern technology and applying the lessons learnt from the past, we are confident that we can overcome these challenges and ensure the success of Sizewell C.

The real-time data from the pressure sensors was encouraging and presented the team with the information required to optimise the pour rate and maximise shutter utilisation for subsequent pours. Depending on the level of formwork optimisation, it was possible to achieve savings of up to 30%*. This would enable the team to save 3 hours per pour, reducing pour time from 10.5 hours to 7.4 hours.

*This was based on a shutter designed to 80kPa for a 9m-high wall, a rate of rise of 850mm/hr with concrete placed in 500mm layers.

Right skills and futureproofing From engineers to on-site operatives, growing skills and nurturing talent across all fields is vital to the success of Sizewell C. This is where educating our work force through C ontinual P rofessional Development (C P D) days and training courses can prove extremely valuable. We can significantly reduce rework and improve the rate at which we get things right first time with proper training, in both formwork and scaffolding.

Other digital tools such as clash detection models also help to identify any problems between temporar y works designs and models of the built environment before they reach site. By using these models on Hinkley Point C, we were able to avoid clashes between the rebar, cast-in embedded steel and formwork elements such as ties and props.

9

The innovative formwork travellers shaping HS2 Copthall Tunnel HS2 Copthall Tunnel

Copthall Tunnel is one of five green tunnels being built along Phase One of the new high-speed rail route. Situated between HS2’s Northolt Tunnel and the Colne Valley Viaduct, the 8 8 0m - long reinforced concrete tunnel will blend into its natural surroundings, covered with trees and plants once construction is complete.

The project is being delivered by Skanska Costain STRABAG Joint Venture, with Kilnbridge appointed to complete the reinforced concrete works.

Making the tunnel a concrete reality has been possible with custom formwork travellers engineered by PERI’s specialist infrastructure team.

As the travellers were expected to be in use over an 18-month period, the main drivers influencing their design were durability, productivity, and sustainability. This meant engineering an efficient and quick system without compromising the qualit y and strength of the final structure.

10

HEAR ABOUT THE WALL TRAVELLER ’S DESIGN FROM THE TEAM

To support the specified construction sequence, PERI’s engineers designed two carriages which enabled the site team to cast the walls and roof slab simultaneously, ultimately accelerating the programme. This comprised four units in total, two for the wall and two for the roof.

The carriages are designed to reduce material, manual labour and cranage as the main operations such as striking, positioning and travelling are completed hydraulically.

The wall forms are built from special modular steel panels. Each set is designed to build 20m-long and 7.5m-high walls.

The panels are suspended from a carriage which is designed using off-the -shelf components from PERI’s VARIOKIT range, with some specially fabricated connection parts. VARIOKIT rails provided additional support for the formwork, reducing through ties to less than half the quantity required in a traditional panel system.

“This is a fully hydraulic system which can lift and move four shutters weighing 128 tonnes in total to enable us to cast the walls of the tunnel. So far, we’ve been able to save around five days per wall in comparison to traditional formwork systems, as we can complete installation and prepare the system for concreting in one day.”

Teresa Martin Project Manager I Kilnbridge

The internal and external formwork on the wall carriages raise, lower and retract hydraulically, eliminating crane-use and reducing labour requirements and cycle time by over 80%.

What’s innovative about this design is that the whole structure moves forward and backwards on wheel units, each capable of supporting 50 tonnes.

Typically, a structure like this would move on rails. A crane or machine would be used to reposition the rails from behind the carriage to the front.

With PERI’s Vulkollan wheels, the carriage travels directly on the base slab, eliminating the need for rails. The wheels also feature hydraulic steering, allowing operators to steer the carriage with the pull of a lever to form the tunnel’s modest curvature.

The roof carriage is just as unique.

It’s built from a mix of special and standard components. In addition to fully supporting the rebar and concrete load, it features hydraulic cylinders which enable the traveller to be lowered, collapsed, pushed under the carriage in front and repositioned to allow rebar fixing and pouring operations to be concurrent.

Hydraulic operations have replaced a lot of the falsework which would usually support a slab pour this deep.

In addition to material, automation has also eliminated labour-intensive assembly and dismantling operations on this project, which would require multiple operatives working at height.

On the topic of formwork, Senior Sales Engineer, Dan Biggs said, “Special steel formwork was ideal for this project as the forms can be reused again and again, so there is an obvious material-saving advantage in addition to timesavings, as panels do not need refacing unlike a plywood faced system would.

We’re very pleased that we’ve been able to reduce material wastage and contribute to reduced carbon emissions, knowing that these steel panels can be reused for future projects without needing to be refaced.”

Following on from the installation of the roof traveller, the next steps will be progressing the tunnel so all three elements – base slab, tunnel walls and roof slab progress concurrently without conflicting. Tunnel construction is expected to be completed by February 2025.

Dan Biggs Senior Sales Engineer I PERI “The design of the roof slab accelerates construction, as the site team are not waiting for the concrete to cure on one section before installing rebar on the next pour.”

EXPLORE THE PROJECT WITH DAN BIGGS

11

XL Hoist fulfils the need for speed on Colindale Gardens Colindale Gardens

Located in Northwest London, the Colindale Gardens development aims to create 4000 high-quality housing o p p o r tuni ti e s an d 11,7 0 0 m 2 of commercial space in the area. Before being transformed into a residential hotspot by Redrow Homes, the site was a former training centre for the Metropolitan Police.

Construction work on Block D, one of four buildings on the project, first started in November last year.

EXPLORE HOW THE XL HOIST MAKES CONSTRUCTION MORE EFFICIENT

Val Fluturas General Foreman Oliver Connell & Son Ltd “We needed to catch up on this project due to the challenging weather we experienced over the winter months. We approached PERI to find an efficient transportation solution to catch up, and that’s when we discovered the magical XL Hoist which is now helping us achieve our target.”

HEAR FROM THE PROJECT TEAM

12

Reinforced concrete frame specialist, Oliver Connell & Son Ltd. is delivering this phase of the project. Adverse weather conditions in the winter months halted progress on the project as the crane was winded off, leaving the site team to find an alternative material transportation solution that would enable them to catch up on an already tight programme.

With the benefit of reduced crane operation, the XL Hoist has been a huge success on this 23-storey tower. The hoist covered four floors, enabling the site team to cycle material from floor to floor as and when required. Using the hoist saved a significant amount of time as opposed to waiting for the crane hook, which would have required additional labour resources.

Site operatives attended product awareness training prior to using the SKYDECK system, which enabled them to safely erect and strike the formwork when constructing the slabs across all floors.

TRIO formwork was used to construct the core walls and columns, with standard panel sizes being used for easy handling and efficient logistics.

13

News Asset Tracking Technology Monitor your inventory in real time

Our Asset Tracking technology enables fast and precise tracking of materials as they are transported from the stockyard to the construction site and back again.

Asset tracking offers construction sites enhanced efficiency, improved security, better maintenance management, and increased accountability, making it an essential tool for any construction project.

PERI UP Cladding

COMING SOON

Alimak STS 300

The safe and flexible enclosure system

Our fastest scaffolding system just got faster

With only a few different components, our new cladding system is an ideal add-on to the PERI UP Scaffolding Kit and just as flexible as the kit itself - whether for simple facade scaffolding or more complex applications. Its extremely low individual component weight and the ability to carry out assembly from a secured position improves safety levels for scaffolders on site.

We’re working in partnership with Alimak to make scaffolding operations easier. The Alimak STS 300 has been developed to work seamlessly with PERI UP scaffolding systems, providing a smarter way of transporting components and material from the ground up to any level.

FIND OUT MORE...

14

Formwork Scaffolding Engineering www.peri.ltd.uk

UK en 02 | 2023