Volumetric Modular - Issue 04

DEDICATED TO THE DEVELOPMENT AND APPLICATION OF VOLUMETRIC MODULAR SYSTEMS

JUL/AUG 2023

ISSUE 4

VOLUMETRIC

MODULAR THE MODULAR FACTOR ADOPTING NEW DIMENSIONS IN BUILDING DESIGN

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ALGECO Radical rethinking required for the needs of today’s diverse building users

YR HAFAN HOMES How Passivhaus design is delivering landmark sustainable modular living

BROWNFIELD DEVELOPMENTS Unlocking the potential for net zero carbon homes in underused locations

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BATHROOM & ENSUITE PODS

PRECISION ENGINEERED QUALIT Y A SSURED BATHROOM & ENSUITE PODS OFFSITE MANUFACTURED TO METICULOUS STANDARDS WITH A CHOICE OF FINISHES AND FITTINGS

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Designed, engineered and manufactured by our multi awardwinning offsite experts.

CONTENTS

HOW DOES IT ALL STACK UP?

Welcome to our special magazine section championing some recent projects and businesses operating in the volumetric modular space within the offsite world. Volumetric modular has become synonymous with offsite and modern methods of construction (MMC) in recent years, especially in conversations surrounding housebuilding. Make UK Modular estimate that modular housebuilders require up to 50% fewer workers to deliver the same number of homes, thanks to the efficiency of the assembly line and the economies of scale inherent in volume manufacturing.

While innovation and digital design is driving the success story of volumetric methods, an uphill struggle still remains for many in the industry to convince clients of its benefits. Ultimately, it is just about taking traditional building materials and then using factory-based manufacturing processes and cutting-edge technology, to produce repeatable sections and components. This factory process feeds into improved quality, reliability, de-risking site-based installation and increasing overall productivity.

Allied to this is that within the factory environment, a path of continuous improvement sees producers swiftly identify, reduce and correct those aspects of production that are inefficient. Over the next few pages, we showcase several developments across the volumetric sector where organisations are doing just that, and you can begin to understand why volumetric modular methods are being investigated so keenly as a way to transform the UK’s built environment.

CONTENTS

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12 | Rollalong

ALGECO James Withey, Managing Director at Algeco Offsite, assesses the scale of the challenges for building users and outlines a useful CPD to help.

Housing association Magna, Wiltshire Council and Dorsetbased manufacturer Rollalong joined forces in 2022 to tackle the housing crisis using modular building methods pledging to build nearly 1,000 new affordable homes by 2026.

14 | Beattie Passive Beattie Passive has announced that the homes at Yr Hafan – the collective housing scheme it handed over to Cardiff Council in 2022 – have been officially certified to the Passivhaus Plus standard by the Passivhaus Institut in Germany.

16 | Enevate Homes Enevate Homes has witnessed recent high demand for volumetric modular that may signal that the proportion of new homes being delivered in this way is set to increase rapidly.

18 | Merit

06 | MPBA Richard Hipkiss, Development Director of the Modular and Portable Building Association (MPBA) explains how MMC is being driven by increased demand of key sectors including healthcare, education and housing.

08 | MTX

Healthcare is a key sector for the volumetric modular sector being able to provide excellent new facilities quickly. Work is now underway at a much-needed new hospital in Berwickupon-Tweed.

20 | ZED PODS

Offsite construction has enabled MTX to achieve faster and more efficient completion of a new general surgery operating theatre at Yeovil District Hospital.

Using a design-led, offsite approach is central to unlocking the potential for brownfield sites. Lalit Chauhan, Design Director for ZED PODS, describes why.

22 | Aquarian Cladding

10 | Wernick Buildings Modular construction pioneer Wernick Buildings recently completed a new healthcare clinic located in Greater London, with volumetric modular proving the perfect solution.

Jazz Rigden, Aquarian Cladding’s Sales Director, discusses the benefits of a brick façade and why the Gebrik system is perfect for modular construction.

24 | Top Hat

11 | Apex Modular Systems A new venture formed by two North East modular construction businesses is aiming to supercharge the offsite construction sector across the UK by offering a fresh dimension in M&E provision.

Taking its modular housebuilding expertise over the Channel to France, TopHat has entered an exclusive partnership with Nexity, France’s largest housebuilder to further advance offsite construction.

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VOLUMETRIC MODULAR

ADOPTING A MODULAR MINDSET The government needs to have a radical rethink when it comes to meeting the needs of today’s building users. James Withey, Managing Director at Algeco Offsite, assesses the scale of the challenges and outlines a useful CPD to help.

1 Health, education and immigration all seem to be constantly in the news and not always for the right reasons.

From the state of school and hospital buildings, through to lack of spaces to temporarily house people entering this country, we seem to be at a stage where the construction industry needs to embrace offsite.

Overcrowded classrooms, shortage of places and substandard teaching spaces are specific issues facing schools. Under the spotlight is reinforced autoclaved aerated concrete (RAAC), which was used to construct thousands of schools and hospitals between the 1950s and mid-1990s but is prone to failure. It is estimated that there are around 700,000 pupils in schools needing major repair.

Of equal concern is the fact that RAAC often exists in the same buildings as asbestos, because both materials were widely used in the postwar building boom. According to ‘The Times’ newspaper there are still 21,500 schools open today with asbestos, while 90% of Britain’s 1,200

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hospitals also contain it. Remediation or replacement of these buildings on any meaningful timescale can only be achieved by unlocking modern methods, a process that would also boost growth, create thousands of green jobs and address the specific challenges currently facing the market.

Seismic Platform The Government has already stated that it has a preference for offsite, although with the scale of the challenges from RAAC alone, this really needs to be accelerated.

Schools and hospitals require a quick solution before more people’s health. We believe that the Seismic platform provides the way forward.

Designed in line with the government’s Construction 2025 targets, Seismic exceeds them in every way, delivering a building that is 75% faster to complete, 70% lower in carbon impact and 47% better value than traditional construction. The standardisation developed for the platform even allows Seismic to compete with other modular solutions, with an improvement of around 30% on speed.

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This transformational efficiency means that it offers a solution for other sectors, too, for example, rapid accommodation for the thousands of people entering the country and having to be housed in expensive hotel accommodation. A situation that is both expensive and far from ideal in terms of safety.

All this is one of the reasons why we’re carrying out a new £3.5million capital investment from Modulaire Group to extend our Carnaby facility in East Yorkshire. It will increase production capacity by up to 70% and create more new permanent jobs. Sustainability and low carbon are at the core of the new investment programme, which incorporates solar PV, recycling, energy efficiency and low carbon initiatives. Our goal is to create a low carbon production facility. This investment to expand the offsite business complements our strategic plan for sustainable growth, which the Modulaire Group has been implementing in recent years.

This new capital investment represents a significant step and reflects how

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2 our offsite business has grown over the last few years. Investment will significantly increase capacity whilst contributing to our journey of being a low carbon business. Our offsite business is in a period of rapid growth and expansion, delivering some truly exceptional projects, whilst pushing the boundaries of R&D and innovation.

We like to think that we have a solution for the issues discussed here.

CPD: How to design for offsite construction With multiple sector and building performance challenges it is important for building specifiers to stay relevant and up to date on new industry trends and practices. As the expectations of each construction project becomes ever more demanding, a process that is pushing offsite construction to the forefront, it is becoming more important than ever for architects to really know the ins and outs of different construction methods. In terms of offsite and modular systems, the CPD walks participants through the process, starting at early design stage, through to construction, modular manufacture and, to for life of the building.

‘Form Follows Function – How to Design for Offsite Construction’ is the title of our new CPD presentation that looks to provide these essential insights. It has been certified by the CPD Certification Service, the world's leading and largest independent CPD accreditation organisation working

across all industry sectors. Our CPD presentation is designed to support industry professionals on what offsite construction can do to help them meet their building performance targets, while still utilising MMC to build safe, efficient and striking structures.

The CPD format uses a Design for Manufacture & Assembly (DfMA) overlay to the conventional Plan of Work to highlight the differences between offsite and traditional construction and the benefits that they create. Early engagement, collaborative working, clear accountability and strong project management are consistent themes of our offsite approach.

The CPD is supported with detailed case studies from leading architects. These illustrate where offsite construction has been used successfully, whilst a Q&A section tackles the questions commonly asked such as fire safety and planning – all selected to share knowledge. In addition, the CPD covers the features and sustainability benefits of offsite construction – a key requirement with a growing number of architects and specifiers – before finishing with practical guidance on design considerations and how building performance can be optimised further.

By the end of the CPD presentation, which we are delivering through online sessions, specifiers will have

‘Form Follows Function – How to Design for Offsite Construction’ is available as a webinar or face to face seminar. The CPD online learning module can be previewed and visitors can register interest on the CPD Certification Service website: https://cpduk.co.uk/providers/algeco-uk

3 a greater understanding of modular construction. They will also gain a technical and practical understanding of the benefits of offsite and modular construction as a whole and feel confident about specifying largescale projects using this technique.

Sustainability is embedded in our approach and is fundamental to everything we do as a company.

This vision is based on the principle that the brand must do social and environmental good.

Making Offsite Count and Debunking Myths We have developed our new CPD specifically for architects and specifiers looking to help their clients access the benefits of modular and offsite construction – alongside elements of economic and environmental, social and governance (ESG). It offers a better understanding of the benefits of specifying offsite to meet with the most up to date building performance requirements.

We encourage specifiers to take up the opportunity offered by our seminars.

They are a great place to ask expert advice for any on-going or future project. As a leading manufacturer our team know their product inside out.

We’re keen to help industry colleagues learn more about offsite solutions - and explode the odd myth along the way.

Our CPD will ensure confidence when specifying offsite construction.

Images: 01. Hatchlands Primary School 02. Pinderfields Hospital 03. Algeco are leading the way in volumetric modular construction and have also designed a CPD to help all those working across the offsite sector

Alternatively, you can request a presentation directly from: www.algeco.co.uk/permanent/cpd

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VOLUMETRIC MODULAR

TRANSFORMATIVE TECHNOLOGY Richard Hipkiss, Development Director of the Modular and Portable Building Association (MPBA) explains how MMC is being driven by increased demand of key sectors including healthcare, education and housing.

1 Scanning the industry headlines, you could not fail to notice that some relatively new entrants to the volumetric modular arena are facing challenging times.

Many consider Modern Methods of Construction (MMC) to be relatively new, but this transformative technology has evolved over many decades. It is hard to believe that Wernick® Group has been around since 1934. Not long after other major players in today’s industry joined the ranks, with the foundation of Portakabin in 1961, followed by Elliott Group (Algeco) in 1963, Pickerings in 1969 and Thurston Group in 1970.

So how have these companies stood the test of time? There is not one simple answer. But in the main it is down to developing technical solutions to overcome inherent industry issues whilst also having a keen eye on the future and anticipating what is coming down the track.

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A simple but effective tactic It is universally agreed that a robust and regular pipeline of work is essential to ensure that the overheads incurred in running the high-tech manufacturing facilities associated with MMC are covered. Planning ahead for the peaks and troughs is essential.

This can be managed in various ways, but experienced operators have a simple and effective tactic. By using a series of interconnecting factories, manufacturing facilities can be expanded at times of high demand and closed off if a project for example, suffers planning delays.

Evidencing value Pre-Manufactured Value (PMV) is another driving force in the specification of volumetric technology in the commercial sector. PMV is a core metric for measuring the level of MMC in a project and is central to the UK government’s procurement programmes. To secure a contract, suppliers are required to show that

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pre-manufacturing will account for 70% of their construction cost, which plays to the strengths of a volumetric modular approach.

Another strategy is acquisition and investment Portakabin has recently confirmed the acquisition of healthcare modular buildings specialist Darwin Group.

The companies say the move will offer significant benefits to healthcare providers across the UK. The acquisition was driven by a shared belief that every patient should have access to world-leading healthcare facilities that empower clinicians and the broader healthcare system to deliver exceptional care.

And whilst Legal & General (L&G) has made the decision to close its modular housebuilding factory citing the impact of the pandemic and planning delays – Aviva Capital Partners (ACP) is investing £20million into TopHat. This equity funding will support TopHat’s

VOLUMETRIC MODULAR

2 major new factory in Corby and the creation of 1,000 new jobs. The factory, anticipated to operate from summer 2024, has been designed to be capable of manufacturing 4,000 ultra-low carbon homes a year and will be Europe’s largest modular housing factory.

The answer to the UK housing crisis Fast-build modular homes are certainly one of the answers to the UK housing crisis. The quality, energy efficiency, speed and sustainable manufacturing processes achieved in a factory environment are difficult if not impossible to replicate using a traditional site based construction approach.

Taking a long-term view, ACP state that this investment was driven by the sustainability credentials of TopHat’s low-carbon homes. In 2025, compliance with the UK Government’s Future Homes Standard will become mandatory. Its aim is to ensure that new homes built from 2025 will produce 75-80% less carbon emissions than homes built under the current Building Regulations. UK housing stock’s operational emissions is also vital for the UK to meet its legally binding net zero targets and modular homes can provide a fast and effective solution.

The MMC sector for category one (volumetric) and category two (panelised systems) is an interesting

3 place to be. The levels of investment and innovation are astounding and as with any transformative technology, there will be hurdles to overcome. Our industry unlike others, has nothing to fear from the legislation surrounding the predicted standards and the road to achieve net zero targets in commercial buildings is a well mapped route. The MPBA and our members

firmly believe that the benefits of manufactured buildings begin in the factory, continue to the construction site and last through the lifetime of the building.

Images: 01-03. Volumetric modular technology has evolved over many decades and is driving innovation across the built environment.

Courtesy Portakabin Group

MPBA The Modular and Portable Building Association plays a key role in supporting all sections of the industry. Leading best practice principles, the association is represented on many committees for the benefit of members. Most importantly, the MPBA ensure evolving government policies and decisions are not made on behalf of the construction industry without due consideration for the impact they may have on the volumetric modular sector. Regardless of the size and type of your business, becoming an MPBA member will open doors to valuable business development, training and collaboration opportunities.

For more information visit: www.mpba.biz

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CASE STUDY

VOLUMETRIC MODULAR

OPERATION OFFSITE

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1 Offsite construction has enabled MTX to achieve faster and more efficient completion of a new general surgery operating theatre at Yeovil District Hospital.

Offsite fabricated steel sections of the external shell were craned into position on the prepared site of a former car park at the hospital before concrete screed floors and premanufactured walls were installed.

The single storey unit includes the theatre suite with recovery rooms, reception and waiting areas, office space and a dedicated staff facility.

Once the single storey structure was complete, the MTX team began installation of mechanical, electrical and plumbing elements, and fitting out including furniture and specialised equipment. A plant equipment enclosure located on top of the building accommodates air handling units and electrical supply panels to serve the self-contained 420sq m building within the original footprint.

Modern Methods of Construction (MMC) are increasingly being chosen by NHS Trusts because they meet Government requirements for adopting offsite construction techniques. They provide additional facilities more quickly with time onsite reduced by up to 50%, reduced costs and a greener build with offsite construction reducing waste by up to 60%.

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The new theatre will principally help reduce waiting times for patients needing day-surgery procedures – breast surgery, dermatology, plastic surgery and other general surgery.

Caroline Osborne, a consultant breast surgeon at Somerset NHS Foundation Trust, which runs Yeovil District Hospital, said: “We’re so pleased to have opened our new day theatre, which means our team of surgeons can perform many more operations at Yeovil. With the day theatre located away from the main hospital building, it has freed up space in our main hospital theatres for the more complex procedures, helping us to reduce the waiting times for patients across Somerset who need operations.

“There has been a real change in the way we perform many operations in Somerset with some specialties able to offer day surgery, where patients can be assessed, treated and go home on the same day as their surgery, rather than staying overnight in hospital.

We’ve had great feedback from patients on this approach.”

MTX worked on the project with Simply Serve Ltd, a wholly-owned subsidiary of Somerset NHS Foundation Trust, which provides a broad range of services to the hospital and other organisations, including management of capital projects.

MTX Managing Director David Hartley explains: “Proven expertise in employing MMC enables us to

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3 quickly deliver high quality new hospital facilities cost effectively.

The operating theatres and other facilities we create for NHS Trusts are specifically engineered for medical use with ventilation systems designed to optimise clean air flow and meet clinical needs. Offsite construction takes place while the site is being prepared, enabling the two activities to be carried our concurrently.”

MTX has extensive experience of working in busy locations within hospital sites, and its staff are skilled in optimising progress while minimising impact on existing clinical services and patients. The former car park at Yeovil District Hospital includes an access route used by ambulances, so specific measures were put in place to manage site movements. For example, the crane lift onto the foundations was timed to minimise impacting other vehicle movements on the site, including ambulances.

Somerset NHS Foundation Trust runs both acute hospitals in Somerset – Yeovil District Hospital and Musgrove Park Hospital in Taunton, along with a quarter of Somerset’s GP practices, services from 13 community hospitals, community-based services and mental health and learning disability services.

For more information visit: www.mtx.co.uk Images: 01-03. Yeovil District Hospital

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BESPOKE SOLUTIONS FOR NHS FACILITIES Modular construction pioneer Wernick Buildings recently completed a new healthcare clinic located in Greater London, with volumetric modular proving the perfect solution.

Crane operatives had to take special care to manoeuvre the modules in a dense area surrounded by other buildings. A second clinic (Aspen Building) housing the Audiology and Ear, Nose and Throat departments was completed in Spring 2023.

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Due to the closure of the previous three-story Roehampton building on-site, Kingston Hospital NHS Foundation Trust was looking for a new purpose-built unit to house its growing outpatient services for the Gynaecology, Audiology and Ear, Nose and Throat departments. After a discussion with the Wernick Buildings team, it was decided that two separate modular healthcare buildings on-site would offer the most timely and costeffective solution to accommodate all three hospital departments. The first building delivered by Wernick was the Gynaecology Outpatient Clinic (Willow Building.)

the planning process, assuring their specific needs and requests were met.

Through a competitive tender process, Wernick Buildings presented a full turnkey solution, which included a complete groundworks package and service connection. Designed for outpatient use, the two-storey BREEAM-rated block offers several HTN/HBN-compliant amenities including consultation areas, procedure and recovery rooms, staff offices, changing facilities and accessible toilets. The reception and waiting area feature an open floor plan, creating a spacious welcome area for patients.

The building is comprised of 30 modules and showcases sleek cladding, PV panels, and a state-ofthe-art plant room on the second storey. Wernick worked closely with ADP Architecture during the design process. Clinic nurses, doctors and other staff were also consulted in

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Clinical Director Meena Shankar remarked on the speed and usefulness of the new clinic. “The building was ready to use very quickly and is very modern and comfortable,” said Meena. “We were excited about being involved with the design team from the beginning to get exactly what we wanted.”

The clinic features a modern interior with a cool green colour pallet. Its interior was designed to help provide a calming environment for patients who may be undergoing difficult procedures. The layout boasts a convenient one-way traffic system to support improved infection control measures highlighted through COVID and includes a patient-sensitive discrete exit.

Wernick was also able to provide two temporary modular office buildings to house other displaced departments immediately following the closure of Roehampton Wing. The building modules were constructed off-site, which allowed for minimal disruption and noise pollution to the surrounding area.

Crews overcame several challenges when transporting and installing the modules into place on the property.

The building site was landlocked by three roads and located at the front of the hospital entrance near an Ambulance & Emergency facility.

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Wernick Buildings has decades of experience in delivering modular solutions in the healthcare sector and is highly skilled at working around live clinical building settings. Design, manufacture and site teams are located in-house, providing you with a single point of contact for peace of mind throughout the project. Wernick’s flexible modular systems provide cost efficiency, shorter and more reliable programmes, and improved quality and sustainability.

Offsite construction methods are attractive to NHS trusts as they can dramatically reduce build programmes. Facilities can be operational in a matter of months, compared to years for many traditional build projects. They also reduce on-site disruption and associated health and safety risks. The Wernick building system is designed to deliver compliant hospital wards and clinical spaces via standardisation with compliancy requirements being applied to building systems. This streamlines the construction process by incorporating pre-approved designs. Aside from integrating standard NHS specifications, modular construction can offer clients the option to create bespoke building designs tailored to their specific requirements.

For more information visit: www.wernick.co.uk Images: 01-02. Kingston Hospital NHS Foundation Trust has benefited from modular construction delivering cutting-edge facilities quickly and safely

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MODULAR EXPERTS JOIN FORCES A new venture formed by two North East modular construction businesses is aiming to supercharge the offsite construction sector across the UK by offering a fresh dimension in M&E provision.

“This partnership trims that saving on manhours further, as customers deal with one business from conception to installation. We know from our 15 years installing Apex Wiring Solutions’ systems that they are the best and with work lining up, we can’t wait to get started.”

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CD Engineering Services (CDE) and Apex Wiring Solutions have joined forces to form Apex Modular Systems (AMS), maximising the strengths of both companies in the design, manufacture and installation of modular mechanical and electrical (M&E) systems.

dramatically increasing the percentage of PMV within offsite facilities.

AMS has already secured multimillion pound contracts, supplying and installing pre-manufactured M&E components, with some of the largest offsite manufacturers in the country, which will see AMS deliver their systems into a range of sectors, including the MoD (Single Living Accommodation modules), schools, prisons and healthcare.

With Government setting ambitious targets to grow offsite modular construction from £1billion to £4billion by 2030, existing offsite construction firms must innovate to improve efficiency and increase productivity to meet the increase in demand. This new partnership has potential to deliver a step change in the industry

Between Apex and CDE there’s 40 years of modular experience.

Combining expertise from both companies, AMS offers a seamless process for customers, from design, to order, to manufacture, delivery and installation. CDE has been at the forefront of building services engineering installations for over 15 years, designing and installing modular and prefabricated systems for all projects.

Speaking about the developments, Managing Director, Darren Charlton, said: “Forming Apex Modular Systems makes perfect sense, bringing together one of the foremost manufacturers of modular systems and the most experienced installers. The benefit of offsite engineered systems is the time savings they offer. Modular systems arrive ready to plug in, saving clients not just hours on large scale projects, but weeks and sometimes months.

Apex Business Development Director, Mike Lewis, added: “We’re very excited about this partnership with CDE and the potential that it opens up. Like ourselves, it’s a North East company with a well-earned reputation for excellence. The modular sector is one of the fastest growing in the UK and offers huge potential for agile businesses skilled and experienced in modular systems. This new venture provides a ‘one stop shop’ for customers, covering both mechanical and electrical systems – a single point of contact that oversees the design, costing, manufacture, supply and installation of modular systems across the UK.” Apex Wiring Solutions manufactures over £12million of modular wiring components each year, and two years ago moved into mechanical systems, investing over £500,000 to create a purpose built manufacturing facility to deliver prefabricated utility cupboards, and mechanical sub-assemblies – a modular ‘plug-in’ system to compliment their existing and highly successful modular wiring business.

The new business is based at CDE’s Stockton’s HQ with manufacturing carried out at Apex’s Durham plant.

For more information: Phone: 01642 714050 or visit www.apexwiringsolutions.co.uk Images: 01-02. This new venture provides a ‘one stop shop’ for customers, covering both mechanical and electrical systems for modular schemes

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HOMES REVOLUTION Housing association Magna, Wiltshire Council and Dorset-based manufacturer Rollalong joined forces in 2022 to tackle the housing crisis using modular building methods pledging to build nearly 1,000 new affordable homes by 2026. today, and we’re pleased to have the opportunity to promote the benefits of modular housing as a response to a nationwide housing crisis.”

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Magna and Wiltshire have now taken another step towards that goal by placing orders for Rollalong to manufacture 109 new, modular homes for five sites across two counties. The partners have used their joint purchasing power to get better value under a money-saving framework created by the South West Procurement Alliance (SWPA).

In Wiltshire, the council will create a further 83 new affordable homes across three sites within the county.

UK accredited by NHBC able to ‘step and stagger’ terraces of houses so that they have more visual variety. Magna and Rollalong have already completed 32 new modular homes across sites in Sherborne, Chickerell and Dorchester.

Rollalong uses precision engineering techniques to manufacture high-quality modern homes as modules in its factory near Wimborne Minster. These are then transported, fully fitted with kitchens, bathrooms and electrics, to sites where they will become attractive, energy efficient homes.

The partners’ latest range of modular house types are built to be ‘net zero in use’, in line with the Government’s proposed Future Homes Standard, which will require new homes built from 2025 to produce 75-80% less carbon. The all-electric homes will be heated by air-source heat pumps, with a thermally efficient fabric retaining warmth and helping residents keep their energy bills lower.

The homes can be tailored to the local, often rural setting, with a range of house types and finishes influenced by customer feedback. The partners also have the only modular approach in the

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Paul Read, Magna’s Director of Sustainability and Investment, said: “These are among the most important new homes Magna has delivered, with our ambition to build the right homes of the right quality in the right places. By collaborating with others and modernising how we build, we are creating homes for local people that will help address the cost of living, energy challenges and contribute towards the UK’s net zero targets.

“Thanks to Government retrofit funding, we also have the opportunity to decarbonise our existing homes, including those neighbouring the new, modular houses at Webbers Piece.

These older homes will benefit from external wall insulation, new windows and doors, and air-source heat pumps.

The timing means we can look at creating a real sense of place in this rural community.”

Steve Chivers, Managing Director of Rollalong, said: “Manufacturing homes offsite in modules is the future for our industry, and our unique partnership provides the volumes we need to make these modern methods of construction work. These are the homes of the future designed for living

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Also, as the modular construction sector goes through turbulent times, Steve Chivers says Rollalong is bucking the trend of some recent highprofile failures in the modular offsite construction sector. “Thanks to our many years of experience, our diverse product range and our long-standing partnerships, Rollalong is not facing the same challenges that others are experiencing in the industry,” he said.

“We have a strong pipeline of work, such as the homes recently ordered by partners Magna Housing and Wilshire Council. With these houses now being produced in the factory, our business is continuing as normal. Working together, we can deliver the volumes that we require using a market tested, BOPAS and NHBC Accepts accredited portfolio of standard house types in any step and stagger configuration and roll out through a regional delivery model.

“These are exciting times as we roll out the delivery of almost 1,000 new net zero carbon ready and net zero carbon living modular homes across Somerset, Wiltshire and Dorset, using offsite manufactured, precision-engineered techniques to modernise and speed up the whole process.”

For more information visit: www.rollalong.co.uk

Images: 01. L-R: Paul Read, Director of Sustainability and Investment, Magna; Andy Mead, Residential Development Manager, Wiltshire Council; Steve Chivers, Managing Director of Rollalong; Mary Bennell, Director of SWPA 02. Modular manufacture can provide zero carbon, energy efficient homes

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VOLUMETRIC MODULAR

PASSIVHAUS PLUS FOR YR HAFAN Beattie Passive has announced that the homes at Yr Hafan – the collective housing scheme it handed over to Cardiff Council in 2022 – have been officially certified to the Passivhaus Plus standard by the Passivhaus Institut in Germany.

First’ philosophy and five key principles of Passivhaus with onsite renewable energy to achieve net zero for operational carbon. As a result, the homes at Yr Hafan don’t just save energy – they generate their own.

Enough energy, in fact, to power the modular homes throughout the year, effectively transforming Yr Hafan into a Passivhaus Powerhouse. This approach significantly reduces heating bills and serves as a highly effective strategy to prevent vulnerable people falling into fuel poverty.

1 It is believed to be the first relocatable residential modular housing development in Europe to achieve the rigorous energy efficiency standard.

This ‘fossil fuel-free’ scheme has been built on the site of a former gasworks in Grangetown, which was acquired

by Cardiff Council in 2020. Rated net zero for operational carbon, Yr Hafan consists of 48 volumetric modular one, two and three-bedroom apartments, and two additional administrative and communal blocks, containing offices, a training room, a training kitchen, a 24/7 medical office and a crèche.

Yr Hafan provides high quality, energy efficient, comfortable and sustainable accommodation for families at risk of homelessness, together with extensive wraparound support services.

Commenting on the scheme, Lynda Thorne, Cabinet Member for Housing and Communities at Cardiff Council, said: “What a wonderful facility Yr Hafan is, a real haven for families during a difficult time. As well as the

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new flats, the Caban Yr Hafan is a focal point on the site, a mini community centre for residents where they can access visiting health services, Into Work support, Adult Learning opportunities, or just come together with neighbours to use the community facilities.

“Nobody wants to be living in temporary accommodation, but we’ve had some great feedback from the families staying at the centre, both in terms of quality of the flats and the support they receive from our staff there. And, of course, the beauty of this type of build means we can move the units to other locations across the city in the future, if necessary.”

Passivhaus Plus The scheme at Yr Hafan is notable for several reasons. Firstly, Passivhaus Plus is a relatively new standard that recognises the production of renewable energy by passive buildings. It combines the ‘Efficiency

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Secondly, the entire scheme was constructed using offsite methods. Yr Hafan was designed in the Passivhaus Planning Package (PHPP) and constructed using Beattie Passive’s ‘Passivhaus-certified’ timber frame build system at the firm’s offsite factory in Norwich, Norfolk. As part of the project, Beattie Passive commissioned data analyst CERCULA to conduct a lifecycle analysis at Yr Hafan over a 60-year period.

According to CERCULA, the whole life carbon impact of the project is 1,460 tonnes, which is 78% lower than a traditional build, resulting in an estimated saving of 5,189 tonnes of carbon – equivalent to 12,067 barrels of oil. Yr Hafan has a net zero carbon operational performance rating, with embodied carbon at 242 tCO2e/m2, which is compliant with the RIBA 2030 Challenge. CERCULA estimates that residents will save a considerable amount on their annual energy bills.

Finally, the entire scheme is demountable and relocatable. This gives Cardiff Council the ability to respond to changing housing needs in the city, without the need for demolition or new building sites – both of which are carbon intensive.

Ron Beattie, Founder and Managing Director at Beattie Passive, said: “Cardiff Council declared a climate

VOLUMETRIC MODULAR emergency in 2019 and has pledged to become carbon neutral by 2030.

We’re very proud of what we’ve accomplished together, not just in terms of the environmental impact of achieving net zero, but also the social benefits of the scheme for everyone involved. Yr Hafan really does show what can be achieved using modern methods of construction.

“The homes are extremely energy efficient, healthy, sustainable, affordable to run, and comfortable to live in. As the saying goes, the cheapest and most renewable energy is always the energy you don’t use.

That’s the beauty of Passivhaus and the Fabric First approach – the energy demand is so low that simply fitting PV panels on the roof spaces was enough to achieve net zero for operational carbon.”

It's no secret that the UK is in the midst of a chronic housing crisis and rates of homelessness are on the rise. Ron Beattie believes that schemes like Yr Hafan can ease the housing crisis, provide homes for the homeless, alleviate fuel poverty and reduce the reliance on private accommodation, such as hotels and B&Bs, to house refugees, migrants and asylum seekers. “Last year, the Home Office disclosed that the government spends around £7million every day on private accommodation.” said Ron.

2 “By investing in our modular homes, local authorities and other housing providers end up with a long-term asset that meets their needs in terms of affordability, speed, environmental sustainability and low energy costs.

The carbon savings are enormous, and the potential lifecycle cost savings for Yr Hafan are expected to exceed £17million when compared to a likefor-like masonry build, with average

energy consumption. CERCULA also estimated that residents would save a considerable amount on their energy bills, and that was before the sharp rise in energy prices last year.”

Images: 01-02. Yr Hafan, a volumetric modular housing scheme officially certified to Passivhaus Plus 03. L-R Rosemary and Isabel Beattie

BEATTIE PASSIVE RECOGNISED IN UK TOP 200 WOMEN-POWERED BUSINESSES Beattie Passive was included in J.P. Morgan Private Bank’s annual list of the UK’s Top 200 women-powered businesses. J.P. Morgan Private Bank and research provider Beauhurst analysed 46,300 companies in the UK and found that 13,255 are either founded, led, owned or managed by women. Beattie Passive was ranked at number 171 in the Top 200.

The report recognises the tremendous contribution that female-led businesses make in terms of development and innovation, raising £5.75billion of private equity investment across 2,097 deals in 2022.

Beattie Passive’s inclusion underlines the high number of women-powered businesses in the East of England, which accounts for 26.7% of the total population by region.

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Rosemary Beattie, Director at the Norwich-based firm, said: “We’re very proud to be named in this report. Construction has traditionally been a male-dominated sector, but that’s changing and addressing the gender imbalance will have many benefits. A shortage of skilled workers is one of the biggest challenges facing our industry, so encouraging more women into construction will help to close the skills gap and widen the talent pool. There’s a very broad range of opportunities out there, so I would urge more women to consider a career in construction.”

For more information visit: www.beattiepassive.com

JULY/AUGUST 2023 | WWW.VOLUMETRICMAGAZINE.CO.UK

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VOLUMETRIC MODULAR

ENERGISING NEW HOMES PRODUCTION Enevate Homes has witnessed recent high demand for volumetric modular that may signal that the proportion of new homes being delivered in this way is set to increase rapidly. where Enevate Homes factory can produce an average-sized home in just 30 days.

Gary Mayatt, Managing Director, says: “Despite the benefits of modular housing, many providers have been loss-making, with momentum stalling and leading to several companies falling into administration last year.

However, the solution to the UK housing crisis appears to be gaining serious momentum since February this year with significant interest from ministers and housing associations.”

Certainly, modular housing has a pivotal role to play in solving the UK’s housing crisis. UK housebuilders and policymakers need to only look to the likes of Japan and Sweden, where offsite manufacturing has been embraced as a way to diversify the supply of new housing, to understand how beneficial offsite methods can be for a country in delivering new housing levels.

1 Enevate Homes, a national and independent provider of modular homes, has seen turnover increase by 118% this year as the need for a sustainable housing solution grows.

The company, which works with many housing associations across the UK, is using a ‘greener’ approach than traditional construction methods and offering a long-term solution to Kent’s housing crisis in particular.

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Enevate Homes, which was founded in 2016, has seen an influx of housing associations, including Greenwich and Dundee, approach them for factory tours and to learn about modular homes in recent months, signalling a start for plans to rapidly produce more homes to provide low-cost social housing. Shona Robinson, Deputy First Minister for Scotland recently visited the company’s 150,000sq ft factory in North Lanarkshire, Wishaw, to discuss the country’s plans for modular living,

WWW.VOLUMETRICMAGAZINE.CO.UK | JULY/AUGUST 2023

Enevate Homes has witnessed its turnover jump from £3.9million last year to £8.5million this year, an increase of 118%, with 250 homes being ordered in recent months.

The company is looking to increase its workforce by 30 to 40 additional employees to cater for the increase of new homes and is working alongside the Ministry of Defence (MoD) and the Career Transition Partnership to give military veterans the opportunity to retrain and join the rapidly expanding business. To cope with the changes, the company recently appointed a new Finance Director and a new Digital Director to the management team, to help support the company as it continues to expand.

“We have seen a significant uptake in modular homes,” adds Gary. “Which is vital, especially if the UK is to tackle some of its biggest issues, such as

VOLUMETRIC MODULAR

3

2 an ageing workforce, a mismatch between the supply and demand of new housing and the urgent need to gear up the economy to meet net zero targets by 2050. The UK currently delivers just 10% of new homes using MMC. We expect this to significantly increase in the coming years as we continue to see a pick-up in momentum. In four years’ time, the modular industry will be a significant part of how we deliver homes in the UK.”

Savills’ Impacts Report predicts that the UK is set to see the strongest growth in modular housing in Europe, estimating that the number of homes delivered using MMC will double to 20% by 2030. Make UK Modular has calculated that the industry will be able to build 20,000 modular homes by 2025. This would equate to a fifth of the 100,000 annual shortfalls, following government targets of 300,000 new homes a year by 2025 (according to

4 official figures, about 204,500 were built in the year to March 2022).

For more information visit: www.enevate.co.uk Images: 01-04. The specification of modular methods for a generation of new homes cannot be underestimated. Courtesy Enevate Homes

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VOLUMETRIC MODULAR

BAD WEATHER BYPASS Healthcare is a key sector for the volumetric modular sector being able to provide excellent new facilities quickly. Work is now underway at a much-needed new hospital in Berwick-upon-Tweed.

Northumbria Healthcare NHS Foundation Trust is one of the largest trusts in the country geographically, providing services to more than 500,000 people across Northumberland and North Tyneside.

Our staff provide care in hospitals, in the community and in people’s own homes.

1

2 The long awaited, new £35million Berwick Hospital is being built one year quicker compared to traditional methods of construction by using offsite proprietary integrated platform technology. Leading industrialised construction and manufacturing specialist Merit, based in Northumberland, has work well underway on the new hospital at its offsite manufacturing factory in Cramlington.

The Merit approach also offers a zero carbon emissions-design, class leading lower energy consumption, enhanced infection control and is technically enabled for the future of healthcare.

The factory recently played host to a visit from Berwick’s MP, Anne-Marie Trevelyan, and nearby Blyth Valley MP, Ian Levy, enabling them to see for themselves the construction of Berwick hospital. They were able to view the start of the build of the 800+ pre-assembled modules (PAMs) and

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17 UltraPODs® that will be delivered to site to form part of the state-of-theart building. The parliamentarians also received a demonstration of Merit’s factory robot, just one of the Industry 4.0 initiatives in progress along with computer numerical control (CNC) technology, automation and digitalisation.

“We are delighted to be working closely with Northumbria Healthcare NHS Foundation Trust and Northumbria Healthcare Facilities Management (NHFM) to build the new Berwick hospital which will be completed by late 2024,” said Tony Wells, CEO at Merit. “It was great to welcome Rt Hon Anne-Marie Trevelyan MP and Ian Levy MP to our factory to show them the work being done on the region’s newest hospital and to explain how different manufacturing processes are being used to improve productivity. We believe that on a larger scale, this solution will bring affordability to the NHS with hospitals being built significantly faster with cost certainty.”

Rt Hon Anne- Marie Trevelyan, MP for Berwick-upon-Tweed added: “It’s really exciting to see the work being done on Berwick’s new hospital and it’s amazing that this area of the country will be the first to benefit from this modern solution to healthcare.”

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Marion Dickson, Northumbria Healthcare’s Executive Director for Nursing, Midwifery and Allied Health Professionals and Project Lead said: “We’re very impressed with Merit’s offsite manufacturing capabilities which can fortunately bypass any bad weather and provide quicker solutions to the build of our new hospital.

“Our new hospital will not only provide high quality healthcare well into the future but will also provide a much-improved environment for our staff and patients, enable additional services to be provided and support staff recruitment and retention. It will be something that Berwick, Northumberland, and the North East, can be very proud of.”

Headquartered in Northumberland, Merit Health is the dedicated healthcare and life sciences division of leading industrialised construction and manufacturing specialist, Merit and employs more than 300 people in the UK and owns further facilities in London and Scotland.

For more information visit: www.merit.co.uk Images: 01. The new Berwick hospital is being built one year quicker compared to traditional methods of construction 02. Marion Dickson (left) pictured with Anne-Marie Trevelyan MP, Merit's chair Kirsty Wells, Merit's CEO Tony Wells, and Ian Levy MP, inside Merit's Cramlington factory

Added value when you choose Uponor for your modular projects PODS, Volumetrics and DfMA You get more than pipes and fittings with Uponor. You also get collaborative support from our expert team, with years of experience in providing value-added services.

Our in-house Design and Estimating team optimise your design to reduce cost and installation time Free certified on-site training with follow-up observation reports if required A dedicated account manager for ongoing support and training refreshers Vast range of reliable fittings and pipes to suit all designs

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S-PRESS PLUS FITTINGS Fast 3 step installation ensure a quick and easy install Best in class flow characteristics 100% joint security with multiple observation windows and a breakaway foil press indicator for verifiable joint security Durable and corrosion resistant

VOLUMETRIC MODULAR

NEW USE FOR OLD LAND Using a design-led, offsite approach is central to unlocking the potential for brownfield sites. Lalit Chauhan, Design Director for ZED PODS, describes why.

1 UK housing supply is under acute pressure with thousands of people on housing waiting lists and hundreds of households in temporary accommodation. Government targets to deliver 300k homes per year are not being met and social-rented homes are not being built in a sustainable way.

UK housing supply is at a crisis point where supply has never really met the demand. Before we start exploring greenfield sites and the myriad of implications this brings, we must test solutions within the limits of urban infrastructure. ZED PODs have been pioneering such an approach.

By considering the requirements of latest design standards, future home standards, space standards and other socio, environmental and financial obligations, along with statutory planning requirements – unlocking brownfield sites seems to us to be the first place to start.

By using volumetric-led modular construction methodology we have been expediting the delivery of these much-required net zero carbon homes in brownfield locations.

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2 CPRE report (State of brownfield 2022) highlighted that more than 23,000 brownfield sites on 27,000 hectares are available for development as recorded on local authority brownfield land registers. Perhaps there’s a clear design approach required to start engaging, planning and delivering housing on these sites. Once explored these sites will naturally come with their own design challenges, but with a concise and carefully approached urban integration/urban regeneration strategies these challenges can easily be designed out.

Modular Resilience ZED PODS have been at the forefront of engaging, designing housing and delivering brownfield schemes.

We have designed and built several high quality, net zero carbon, awardwinning housing schemes in last three years. Our inhouse design team have shown through successful delivery of numerous social-rented exemplar housing projects how ‘difficult to build’ sites can be ‘built to last’ using flexible designs yet volumetric buildings having a long-term design approach.

By delivering these projects with our standard specifications to achieve as built SAP A 100+, we not only have

WWW.VOLUMETRICMAGAZINE.CO.UK | JULY/AUGUST 2023

set very high design standards but also raised the bar for the industry. We have demonstrated how to explore actual strengths of modular buildings in delivering high quality projects aligned to client’s budget and delivery timeframe.

Bespoke Modular ZED PODS have pioneered the strategy to bridge the gap between standardisation and design flexibilities in response to planning and the client’s requirements. Without compromising the core values to deliver high quality, our net zero carbon homes have been considerably exceeding the building regulation requirements on all fronts.

Delivering brownfield schemes come with unique challenges and requirements. Whilst its not to be approached lightly, especially for volumetric modular homes, when done correctly it creates attractive and highly desirable urban spaces to meet specific needs and requirements.

Site specific issues like ground contamination, active flood plains, conservation areas, existing below ground services, grid reinforcements, etc require a tailored design approach and flexibility with an integrated mindset.

VOLUMETRIC MODULAR

3 Our housing scheme in Newport, Wales required us to think hard about finishes to comply and successfully achieve full planning. It also required an integrated delivery team to address the site constraints and delivery of the scheme. By working closely with the client, the planning consultants and leveraging local knowledge we delivered an award-winning scheme within agreed budget and provided much needed homes in a muchneeded location.

No Two Schemes are the Same Two different sites, both underutilised council car park’s and outwardly similar in nature had very distinct sets of issues and required completely unique design approaches. The range from ground conditions such as made ground depths, buried services, site gradients, addressing flood requirements and deciding whether to progress with contemporary versus traditional elevation treatments, emphasise the need to be flexible in our approach but both schemes demonstrate what can be achieved when such an approach is taken.

A scheme in Ashford recently achieved planning in an active 3A flood plain with archaeological interest, ecological interest, TPO’s, nutrient neutrality assessment, restricted vibrations zone and an existing sewer line through the site. By not shying away from these issues and embracing them in the design approach, ZED PODS inhouse design team was able to create a bespoke development of 23 dwellings.

The exemplar schemes clearly show what can be achieved in the most

difficult of brownfield schemes and emphasises how our approach to urban regeneration can unlock the potential for social homes in the most challenging of circumstances that would put off most traditional housebuilders, let alone volumetric providers.

Combination of construction best practice and modular manufacturing know-how means we can deliver a factory-finished modular scheme, built on a 3m high metal podium above the ground floor level to avoid flood levels. We drew on our knowledge and experience from our previous schemes in Bristol and Bromley to address this more challenging site and create a three-storey building over the podium with landscape features to create a functioning and highly desirable scheme. The scheme was designed using the councils full BIM compliance process, and has already won the prestigious ‘Sustainability Award’ from the Constructing Excellence (London and South East).

Not perturbed by flood plain issues we have also demonstrated that even on the edge of a conservation area with protected views, made ground of up to 3m, historic discontinued sewer line, SuDS and SAB requirements, and a 25–30-degree natural slope, delivering much needed homes in a town centre location is possible. Our early engagement with the client helped us to achieve a 100% affordable twelve one bedroom, one person NDSS complaint, self-contained dwellings on such a difficult site in Newport. Responding to planning

requirements in conservation area and local characteristics, we incorporated a render finish façade with wrought iron style railings, glass entrance doors, green wall, rain gardens, Solar PV facing away from the conservation area and protected views.

One size clearly does not fit all when it comes to unlocking brownfield sites, especially with volumetric design, but if you approach a site in the right way whilst integrating the design and build processes from the outset in a collaborative way, there is no reason we can’t unlock brownfield sites in the most challenging of environments.

ZED PODs have shown that delivering high quality homes, which exceed our carbon commitments and future homes standards, is not only possible but also creates desirable homes that receive positive feedback from clients and tenants alike. If we respond to the local context, include local people, adapt to local materials, existing brownfield sites can create living spaces which can be enjoyed and appreciated by the users from inside to out. Perhaps a new lexicon of ‘Bespokulerauty’ in volumetric design is the best way forward to marry standardisation and design flexibility so that no underutilised urban space is excluded from delivery of much needed homes the UK is crying out for.

For more information visit: www.zedpods.com Images: 01. Lalit Chauhan, Design Director, ZED PODS 02. Henwood, Ashford 03. Hill Street, Newport

JULY/AUGUST 2023 | WWW.VOLUMETRICMAGAZINE.CO.UK

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VOLUMETRIC MODULAR

GO MODULAR FOR A MODERN BRICK-BUILT SOLUTION Brick façade system supplier Aquarian Cladding has launched Gebrik Modular for the modular housing market. Jazz Rigden, the company’s Sales Director, discusses the benefits of a brick façade and why the Gebrik system is perfect for modular construction.

On the environmental side, using modular brick cladding reduces carbon footprint simply because thin brick slips require less energy and fewer materials to create. The modular system equals fewer deliveries to site, cutting down on fossil fuel consumption, plus there is much less waste disposal needed on site.

1 British construction sites get more than their fair share of adverse weather. Yet with the cost of labour and materials rising quickly, construction companies are looking for more methods of decreasing the variables by relying on less expensive and weatherdependent solutions.

In the UK, the humble brick has traditionally been – and remains – a cornerstone of construction, particularly in the domestic sector.

That said, significant problems are attached to building with bricks, and they’re not all weather-related. For a start, there is a national shortage of bricklayers, which means that labour costs are higher than they should be.

There are also rising costs associated with the manufacture and delivery of raw materials, including bricks, and the environmental impact of producing them. Finally, there is the fact of assembling everything onsite – and once again we return to our unpredictable weather.

All of which suggests that a smarter approach is needed if we are going to continue with brick-based construction, and the answer is twofold – using a brick-cladding system that comes in at about a quarter of the weight of traditional bricks and is also modular, meaning that it can 22

2 be constructed offsite and can be delivered and applied at speed.

A brick façade is exactly that – a covering made of fired clay brick slips cast in insulation and supplied in a wide variety of traditional and modern formats, Flemish and stretcher bond being just two of these. A brick façade doesn’t corrode or rot. In fact, compared with other facades it improves with age and doesn’t show weather-related degradation. Brick facades come in a wide range of colours and finishes. For example, the Gebrik system has more than 700 clay brick finishes, giving designers and customers all the creativity and flexibility, they need to get exactly what they want from the façade.

The demand for new housing across the UK means that certain factors, for example weather conditions and an on-going shortage of manual labour, need to be addressed as a matter of urgency. Modular brick cladding that is built offsite and delivered in bulk helps to reduce build programme timings and costs, while increasing flexibility around construction sequence. The result is a much faster and efficient build – for example, Gebrik cladding is fitted in an average of 5/6 days compared to around four months to build a house out of full-sized bricks.

WWW.VOLUMETRICMAGAZINE.CO.UK | JULY/AUGUST 2023

This leads us on to issues around on and offsite efficiency. Increasingly, construction firms are seeing the sense in working in a more modular way, i.e. putting together as many components offsite and under controlled conditions, then delivering in bulk. In an era of rising costs, labour shortages and deep market uncertainty, increasing efficiency is key, so a brick cladding solution like Gebrik is now at the front and centre of up-to-the-minute modular methods of building houses. Made under factorycontrolled conditions, it is lightweight and is supplied in kit form, aligning it with other offsite modular solutions.

Additionally, it’s easy to install, and training in its installation takes a fraction of the time it does to teach someone how to lay bricks – plus it’s free.

The brick-built house is an important and lasting part of the UK’s architectural history. Yet with changing times and more modern ways of building coming into view, the modular brick façade is an exciting, innovative product that chimes perfectly with the brick-built tradition while offering an efficient and flexible solution to the demands of the modern construction industry and its customers.

For more information visit: www.aquariancladding.co.uk Images: 01. Jazz Rigden, Sales Director, Aquarian Cladding 02. Modular brick-cladding systems can be constructed offsite and can be delivered and applied at speed

VOLUMETRIC MODULAR

EXPORTING EXPERTISE Taking its modular housebuilding expertise over the Channel to France, TopHat has entered an exclusive partnership with Nexity, France’s largest housebuilder to further advance offsite construction. industrialisation to develop highquality, innovative, and efficient homes that significantly improve our delivery times and costs. This is the beginning of an exciting adventure.”

1

2

TopHat will bring its expertise and experience in delivering modular construction to the partnership, while Nexity will provide its knowledge of the market and French offsite construction and development programs.

efficient products. Jordan Rosenhaus, CEO and founder of TopHat, said the development marks TopHat’s expansion into Europe and they plan on applying and deploying the same precision manufacturing techniques that have helped them address the UK’s housing crisis. He said: “In partnering with Nexity, France’s leading residential development, we will benefit from Nexity’s tremendous local market experience, which will combine with TopHat’s best in class platform to speed up the delivery of affordable, high-quality, energyefficient homes.”

TopHat is currently building Europe’s largest modular housing factory in Corby, Northamptonshire. The new factory will employ 1,000 people working alongside the most advanced housebuilding robots operating at scale in the UK. TopHat’s first factory, based in Derby, has a current output of up to 800 homes a year. The business recently announced a successful fundraise of £70million.

For Nexity the partnership with TopHat is in line with its Imagine 2026 strategy of offering quality, affordable, and low-carbon housing. Building upon its experience as a leader in low-carbon construction in France, Nexity aims to have 10% of its housing production completed in factories by 2028. The company is France’s largest housebuilder, having delivered over 18,000 homes last year – which is similar to the output achieved by Barratt Developments, the UK’s largest housebuilder.

By partnering with TopHat, Nexity aims to accelerate housing delivery times, offer the highest environmental standards to its customers, and develop affordable and energy-

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Veronique Bedague, CEO of Nexity, added: "Low carbon and industrialisation are two key drivers of our Imagine 2026 strategy, enabling us to better meet our customers’ expectations, affirm our low-carbon leadership, and control construction costs. Our partnership with a leading industrial player in Europe, combined with our experience in low-carbon offsite construction, allows us to confidently envision the acceleration of this new industrial sector in France and actively contribute to the ecological transition.”

Benoit Mainguy, Director of Construction at Nexity, said: “Nexity has delivered over 2,000 offsite prefabricated timber frame homes and possesses real expertise. We are delighted to collaborate with a committed expert in construction

WWW.VOLUMETRICMAGAZINE.CO.UK | JULY/AUGUST 2023

As TopHat accelerates growth, it recently appointed ex-JCB boss as Chief Financial Officer (CFO). David held the CFO role at blue chip brand JCB – the £4billion turnover privately held company with significant operations in the UK, India, US, Brazil and China – for almost six years from 2016. Harnessing 20 years of experience in a global organisation that provides product development, manufacturing and financial services, David will enhance TopHat’s Board and Executive team as the company enters a period of rapid growth. “I am delighted to be joining a business which is harnessing technology and leading manufacturing processes and bringing this to homebuilding at scale,” said David Brown.

“Manufacturing houses in factories is a critical part of tackling the nation’s housing crisis and TopHat is at the forefront of this dynamic sector.”

On the new appointment, Jordan Rosenhaus said: “As a senior leader from a major manufacturing business, David brings with him the type of experience that will help us continue to revolutionise house building through the application of cutting-edge technology and lean manufacturing techniques. We’re delighted to have him on board as we enter an exciting growth phase.”

For more information visit: www.tophat.io Images: 01. TopHat is pioneering robotics and technologically advanced factory manufacture 02. L-R Veronique Bedague, CEO, Nexity and Jordan Rosenhaus, CEO, TopHat

AN IMPRESSIVE DISPLAY OF VOLUMETRIC TECHNOLOGY

The OFFSITE EXPO CPD Masterclasses will focus on key industry innovations and will provide a comprehensive and balanced perspective on this rapidly emerging sector from a host of UK

Speakers Include Representatives From:

pioneers.

VOLUMETRIC MODULAR MASTERCLASS

Wednesday 20 September 13:50 – 15:10 Explore Offsite Theatre

REGISTER YOUR FOC TICKET TO THE OFFSITE EVENT OF THE YEAR...

WWW.OFFSITE-EXPO.CO.UK/BOOK

DATE FOR YOUR DIARY If you are interested in learning more about offsite construction and the associated manufacturing processes then the following industry events may be of interest:

2023 19 & 20 September

Offsite Expo 2023

Coventry Building Society Arena

www.offsite-expo.co.uk

Offsite Expo brings together those who are driving change in the construction sector. The event will play host to the leading UK and international offsite manufacturers and component suppliers over two days showcasing a broad spectrum of panelised, volumetric modular solutions, pod and prefabricated MEP solutions, as well as the latest in Digital and BIM technology.

19 September

Offsite Awards

Coventry Building Society Arena

www.offsiteawards.co.uk

Taking centre stage at Offsite Expo, the Offsite Awards will be a major coming together of the industry where over 500 guests will gather to celebrate

22.09.20 ground-breaking achievements and the pioneers who are developing radical new offsite technologies, innovative product developments and landmark RICOH ARENA - COVENTRY Co-located with

projects using factory-based methods.

04 October

Structural Timber Awards

NCC, Birmingham

www.structuraltimberawards.co.uk

Timber continues to stand at the core of success across so many sustainable construction projects. This, combined with enhanced speed and performance benefits, are just some of the reasons for the abundance of exceptional projects. The Structural Timber Awards provide one of the most effective platforms to promote brands or companies alongside the best of the best.

12 October

British Offsite Factory Tour

Essex

www.insideoffsite.co.uk

Following the opening of their new factory in July, British Offsite are providing high-rise industry experts (including tier one main contractors & developers and architects) with the opportunity to take a tour of their new premises. To register your interest or for more information, please contact jessica.holland@radar-communications.co.uk

2024 15 March Tall Buildings Awards

19 & 20 March

2020 Tall Buildings Awards

Tall Buildings Awards 2020

16 April

2020 Tall Buildings Awards

14 May Tall Buildings Awards 2020

FOCUS ON

FRAMING

30 May

10 YEAR ANNIVERSARY

12 July

Modular Matters

West Midlands

Structural Timber Conference

Birmingham

www.modularmatters.co.uk

www.structuraltimberconference.co.uk

The groundswell of interest in engineered timber is driven by both technological advances and concern for the environment and sustainable construction practices. Experts from the structural timber sector will come together to address timber’s use in the construction industry as a versatile and natural material undergoing a contemporary design resurgence.

West Midlands

www.focusonframing.co.uk

The only specialist event of its kind, Focus on Framing provides a solution for light steel frame professionals looking to gain a greater understanding of the latest advances and best practise principles from sector experts. Through informative speakers and case study presentations the seminar will focus on the fast-track non-combustible solutions that are having a significant impact delivering outstanding buildings across all construction sectors.

Online

www.offsiteawards.co.uk

Returning for its tenth year, there will be 25 categories that cover every aspect of the industry from hybrid and modular technology to engineering and installation, ensuring that all aspects of the offsite building process is celebrated - recognising the design and technology that makes these inspiring projects possible.

Structural Timber Awards Entry Deadline

Online

www.structuraltimberawards.co.uk

Featuring compelling examples of what can be achieved using the most natural and sustainable of materials, the 2024 Structural Timber Awards will be a celebration of not only outstanding projects and inspiring individuals, but the coming together of an industry.

Innovate Awards Entry Deadline

Online

More information coming soon.

FULL 2024 EVENT CALENDAR COMING SOON

26

www.tallbuildingsawards.co.uk

Modular technology is ever evolving and to help keep pace with this fast-moving sector. Presenting an insight into the future of construction, this event represents a great opportunity to gain industry intelligence and network with those who are at the forefront of the volumetric modular sector.

Offsite Awards Entry Deadline

10 YEAR ANNIVERSARY

Online

Tall buildings present unique challenges in terms of both design and construction. Their sheer scale demands that particular attention is paid simultaneously to strategic and detailed issues. The Tall Buildings Awards celebrate those that are developing unique design and engineering solutions to maximise space in city centres where demand is high whilst creating a legacy of iconic superstructures that are transforming the UK's built environment.

Focus on Framing

Tall Buildings Awards 2020

21 June

Tall Buildings Awards Entry Deadline

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Coming Soon

Wernick Group’s commitment to a sustainable future

Specialists in modular construction

WERNICK MODULAR BUILDINGS DELIVER...

MINIMUM

ON-SITE TIME

50+YEARS DESIGN LIFE

CONTACT US TODAY 0800 18 18 22 | www.wernick.co.uk buildings@wernick.co.uk

SUSTAINABLE CONSTRUCTION

FLEXIBLE EXPANDABLE

FULL PROJECT

MANAGEMENT

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FIRST-CLASS PERFORMANCE Delivering more light steel residential structures than any other European producer

At Fusion, we are leaders in light steel framing solutions, a modern method of construction that brings huge benefits to our clients. Our light steel solutions and accompanying products offer outstanding precision, efficiency, adaptability, sustainability and performance. Using digitally enabled processes, we work closely with our clients across a range of schemes to help them achieve exceptional results.

Whatever your project, speak to us today to find out how we can assist you.

fusionsteelframing.co.uk 01604 263633 FUSION HOUSE, SCIROCCO CLOSE, MOULTON PARK, NORTHAMPTON, NN3 6HE

Disclaimer: While Fusion provides advice and data on fire protection to its structure, the Company does not provide any guarantees or warranties for fire protection. Fusion is not responsible for the overall fire performance strategy and project-specific detailing of a building, nor the fitting of the components which provide this protection. Advice should always be sought from a suitable qualified and experienced fire engineer on any aspect of a project which may affect a building’s performance in a fire.