Light Steel Framing Magazine - Issue 2 (October 2020)

ISSUE 2 | AUTUMN 2020

LIGHT STEEL FRAMING MAGAZINE THE L ATEST IN LIGHT STEEL FR AMING TECHNOLOGY DEVELOPMENT

EOS PARTNER WITH OSCO HOMES TO DELIVER GROUNDBREAKING

LIGHT STEEL FRAMING MAGAZINE SOCIAL HOUSING SCHEME

P16 OFFSITE AWARDS BEST USE OF STEEL

P26

P38

PRODUCT ORIENTATED APPROACH

FROM MINORITY TO MAINSTREAM

Award-winning steel framing solution at University of Sussex

Call for Publicly Available Specification for large scale prefabrication

Industry insight on the exciting progression of the offsite sector

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FIRE SAFETY FOR STEEL FRAME SYSTEMS

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We have developed a wide range of fire-stopping products and systems that meet the requirements of current national building regulations for applications including ceilings and floor and wall compartmentation – with at least an equal fire performance rating to that of our Cavity Barrier or Fire Stop.

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We’re proud to be new members of the LSFA

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WELCOME

PUBLISHING

Welcome to the latest issue of Light Steel Framing Magazine providing some news and views from the industry and published in partnership with the Light Steel Frame Association – an organisation set up to support the overall objectives and growth of the sector.

FRONT COVER: EOS - Pennine Close PRINTED ON: PEFC 16-33-576 paper stock by Buxton Press

PUBLISHER: Light Steel Framing Magazine is produced in partnership with the Light Steel Frame Association and published by Radar Communications: ©Radar Communications Ltd.

The UK is a world leader in steel construction both commercially, technically and in terms of quality. The industry is also making dramatic improvements in productivity and efficiency levels and take-up of digital tools. According to research carried out by independent consultants Construction Markets – steel continues to be overwhelmingly the structural framing material of choice.

The survey showed that steel now has a 72.5% share of the multi-storey office market and a 60.9% share in the ‘other multi-storey buildings’ which includes retail, education, leisure and healthcare sectors.

Radar Communications Ltd, 5 Darwin Court, Oxon Business Park, Shrewsbury, Shropshire. SY3 5AL T: 01743 290001 www.radar-communications.co.uk

Construction output increased by 17.6% in July 2020, from the initial lockdown drop. But output in August 2020 remained 10.8% below the February 2020 level.

The COVID-19 pandemic has sadly recorded a resurgence and hopefully this will not impact further on the construction industry and the many livelihoods it supports.

SUBSCRIBE TO RECEIVE: www.lightsteelframingmagazine.co.uk ADVERTISING ENQUIRIES PLEASE CONTACT: Julie Williams // T: 01743 290001 E: julie.williams@radar-communications.co.uk

In this issue we celebrate successes at the Offsite Awards featuring the winner and finalists in the Best Use of Steel category. The first ‘virtual’ Offsite Awards – hosted online by the ‘humungous’ Mark Durden-Smith obviously wasn’t what was originally planned but the quantity and quality of entries surpassed previous years. As one of the judges it is always amazing to see the awesome work being delivered across the country.

SEND US YOUR NEWS: Gary Ramsay // T: 01743 290001 E: info@lsf-association.co.uk FOR ENQUIRIES PLEASE CONTACT: E: info@lsf-association.co.uk DISCLAIMER: The content of Light Steel Framing Magazine does not necessarily reflect the views of the editor or publishers and are the views of its contributors and advertisers. The digital edition may include hyperlinks to third-party content, advertising, or websites, provided for the sake of convenience and interest. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any advertising or products available from external sources. No part of this publication may be reproduced or stored in a retrieval system without the written consent of the publishers.

All rights reserved.

For those operating in the industry and associated supply chains, the Light Steel Framing Magazine presents a great opportunity for everyone to have their say – so if you have an industry issue, innovative product or a special project that you feel is worthy of a mention in the next issue – then get in touch via the usual channels.

Finally, a special thanks to all our contributors, advertisers and supporters in these seemingly endless difficult times.

Gary Ramsay Consultant Editor info@lsf-association.co.uk

CONNECTING THE UK OFFSITE INDUSTRY Online information centre offering industry news, project profiles, technical downloads and learning resources tailored to the offsite sector.

WWW.OFFSITEHUB.CO.UK LIGHTSTEELFRAMINGMAGAZINE.CO.UK

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Shaping the

SUPPORTING THE DEVELOPMENT OF LIGHT STEEL FRAME CONSTRUCTION DEDICATED LIGHT GAUGE DIVISION

Our dedicated supply only division are happy to help with customers design and installation queries.

SMD

FLOOR DECK SOLUTIONS

Our product range and crushed end finish is perfect for the light gauge solution.

Structural Floor and Roof Solutions

DEDICATED PRODUCTION LINE

Due to demand, our dedicated production line manages large volumes and quick delivery times.

www.smdltd.co.uk

In this issue...

CONTENTS

06

A Groundbreaking Social Housing Scheme

08

Industry News

14

LSFA Design Guide

16

Offsite Award Winner – Best Use of Steel

22

Project Profile

26

Moving Towards a Product Orientated Approach

36

Why Steel is Sustainable

38

The Transition from Minority to Mainstream

Providing not only much needed affordable homes but also creating opportunities for those distant from the labour market to gain training, skills and sustained employment.

Highlighting the latest launches, partnerships, consortiums, project developments and building technology innovations in the UK light steel framing sector.

Members of the LSFA have formed a working group and are now collaborating to develop a Design Guide which will offer in-depth insights into light steel framing technology.

The winning project is a benchmark example of how Fusion’s ‘product rather than project’ approach assisted in the delivery of an outstanding steel framing solution.

Featuring an exclusive £10million residential development in Kent of 36 high-end contemporary apartments set within beautiful surroundings overlooking the English Channel.

A call for more involvement from light steel frame manufacturers to support Publicly Available Specification (PAS) for large scale prefabrication.

Understanding how building materials perform in use, and what happens to them at end-of-life, has an important role to play in achieving a more sustainable construction environment.

Industry insight on the progression within the offsite sector over the past five-years to the present state of this evolving market.

Driving growth and supporting the objectives of the light steel frame industry

JOIN US TODAY!

www.lsf-association.co.uk

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COVER STORY EOS

PENNINE CLOSE A GROUNDBREAKING SOCIAL HOUSING SCHEME

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WELL-KNOWN FOR DEVELOPING LASTING PARTNERSHIPS, EOS HAS ONCE AGAIN COLLABORATED WITH OSCO HOMES TO PROVIDE AN INNOVATIVE STEEL FRAMING SOLUTION FOR A NEW DEVELOPMENT IN ST HELENS FOR NORTH WEST HOUSING GROUP, TORUS.

This is truly an inspirational enterprise which not only provides much needed affordable homes but also creates opportunities for those distant from the labour market to gain training, skills and sustained employment. More than three years ago EOS supported OSCO Homes in a ground-breaking development at The Lockies where offsite construction was used as the medium to provide ex-prisoners from HM Prison Hindley, Greater Manchester, many with no construction knowledge – with the skills and training needed to gain employment. OSCO supported each individual in finding work on release and the research showed the re-offending rate dropped dramatically to around 10% of the national average.

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The OSCO skills journey model is now being rolled out across many projects including Pennine Close in St Helens.

The development consists of 10 houses built for affordable rent and is part of a significant investment in the area as the housing group Torus, looks to build 5,300 houses in its heartlands by 2024.

THE OPTIMUM SOLUTION Improving levels of occupant safety together with increasing the quality and energy performance of the build was a key priority for Torus Developments.

Making use of the latest products, technical know-how and manufacturing excellence – fast-track steel framing systems provided the solution.

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Providing crucial time and cost benefits – an offsite system approach ensures the outcome is more predictable and repeatable, eradicating the risk of on-site variability. On this occasion the custom-made range of walling and flooring systems for the Pennine Close development were designed and manufactured to exacting tolerances in the EOS factory complete with M&E service channels and openings, then supplied as a complete kit of parts to the OSCO Homes factory. There an expert team led a group of low and multi-skilled operatives to assemble the panels including Weather Defence external sheathing and Rock Mineral Wool insulation with only the Siniat

COVER STORY EOS

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03 Frameboard internal boarding being installed on-site. All ancillary products and fixings were manufactured and supplied by EOS. The panels were then factory finished by the OSCO Homes team complete with doors, windows and a brick slip cladding system supplied by Wetherby Building Systems.

POSITIVE IMPACT Chris Bowen, Managing Director of Torus Developments, said: “The project highlights how Torus are embracing innovative ways to not only provide high quality housing, but to also shape the communities we operate in. It is not just about simply building as many homes as possible; it is also about the wider influence we have and providing opportunities for the people who make up our communities is a big part of that.

“This project is very rewarding in that people who perhaps may have previously been left behind by the system are given a second opportunity, they learn a trade and significantly increase their prospects when they are released.”

04 INNOVATION THROUGH COLLABORATION Embracing a world-class manufacturing ethos and optimising design for manufacture and assembly (DfMA) principles are at the heart of the EOS operation. With a culture of constant improvement, EOS invest in the company’s advanced manufacturing facility together with the research and development of new and innovative offsite systems – the resulting benefits are passed onto customers.

The EOS team are well known for building excellent working relationships based on customer needs. Through collaborative working and by forming strategic alliances, the leading steel framing contractor provide specialist services to businesses, large and small, including some of the most prominent companies in construction.

EOS offer a comprehensive expert partnering service, for conceiving, designing, and manufacturing light gauge steel frame solutions for the

exacting requirements of construction industry. EOS work with our clients such as OSCO Homes to develop collaborative strategies and build trust through reliability and delivery.

EOS operate a range of partnering solutions and are always looking for new opportunities to work with new collaborators on outstanding projects.

To view client testimonials or video case studies go to the EOS Video Vault: www.eosframing.co.uk/ information-centre/video-vault

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

IMAGES 01-04.

The scheme created much needed affordable homes together with employment and training opportunities for those distant from the labour market.

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INDUSTRY NEWS

MAXIMISING MMC IMPACTS FOR SMES AND SOCIAL HOUSING

THE LSFA ANNOUNCES THE APPOINTMENT OF INAUGURAL CHAIR Since its introduction at the Focus on Framing conference in June 2019, the Light Steel Frame Association (LSFA) has grown in stature and numbers – now including some of the most prominent names operating in the sector.

As the construction industry looks to raise the bar to meet building regulations banning the use of combustible materials on and within external walls of specific residential sectors above 18m – the light steel frame industry has witnessed unprecedented demand for non-combustible panelised and volumetric modular systems.

The sector is more agile, advanced and digitally savvy than competitors in other offsite material groups and unlike some associations, those operating within the light steel frame sector are more committed to collaborating for the collective good of the industry.

This united approach was in evidence at the LSFA’s Steering Group meeting recently where Mike Fairey was unanimously voted in as the Association’s new Chair. Mike is Joint Director and Owner of Salvesen Insulated Frames Ltd and back in 2010 with his partner Tom Salvesen, bought the assets of Fusion Building Systems with the objective of firmly establishing the business as a UK leader in the offsite manufacturing of light steel frame superstructures.

Mike’s engineering career began in the early 1980s when he completed a five-year engineering apprenticeship in prototype automotive design and testing. Later in his career as an informed and respected member of the light steel frame industry,

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Mike was appointed to the Board of The Housing Forum in 2016 to provide insight and become the voice of offsite construction. He now uses his extensive expertise to champion offsite construction methods, helping to educate and transform approaches for housebuilding in the UK. “Mike Fairey said of his appointment: “It is a real opportunity to chair such a forward-thinking group of construction professionals. My primary objective is to agree formal collaborations with other key industry associations and bodies such as The Housing Forum.

We are galvanising the sector as we’re on the cusp of a major opportunity which has been driven by building regulations and the potential to further reduce the restriction of non-combustible materials in external walls to 11m. The sustainability and longevity benefits combined with the fire resistant properties mean that light steel framing systems are a vital offsite technology that can be used in so many building types and applications.”

Interested to find out more about the benefits of steel?

The Light Steel Frame Association (LSFA) has been established to influence legislation, regulation and to support the overall objectives and growth of the steel framing sector. The Association works with members to raise awareness of the performance, productivity and sustainability benefits of steel.

If you require more information on steel framing systems or are interested in joining, go to: www.lsf-association.co.uk or call Hannah Jones on 01743 290 001

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Technical Design Services Group (TDSG) has joined Stellar – a consortium of academic, technical, industry and end user stakeholders, that will work together in supporting SMEs and Social Housing Providers to embrace Modern Methods of Construction.

Created and lead by Totally Modular, a leading manufacturer of volumetric modular homes, the consortium’s intention is to produce a common steel framing platform that can be utilised without the need to start from first engineering principles each and every time designs change, together with demonstrating that a satellite manufacturing facility can be fully operational within a shortened time frame, whilst negating the need for a multi-million pound capex investment.

TDSG’s specific involvement will be to utilise the in-house expertise of each of their sister companies TDS and Design4Structures, to provide structural engineering services as well as BIM compliant design and detailing including development of parametric modelling tools. Other key contributors to the Stellar initiative are Citizen Housing, Spacious Place, Wolverhampton University and Jali.

Daniel Leech, CEO of TDSG commented: “We are very excited to be able to focus our energy on developing parametric modelling tools in order to streamline the BIM process and demonstrate what can be achieved by utilising the latest construction technology solutions available on the market.”

To find out more go to: www.tdsg.co.uk

CHANGING THE WAY FOR SPECIFIERS FASTENERS FOR BLIND FIXING APPLICATIONS

Thin Wall Bolts were developed to address the need for a blind fixing to be used into lightweight steel sheet or cladding material.

After installation, a neat, low profile head is left with no stud.

The Thin Wall bolt has a strong shear capacity and is available in A2 stainless steel or with a zinc electroplate finish.

• Quick and easy to install.

• No over-sized hole required.

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APPLICATIONS • Cladding Materials • Lightweight Steel Sheets • Light Steel Framing

FLUSH FIT VERSION COMING SOON

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INDUSTRY NEWS

SEISMIC SHAKES UP MMC Seismic II has been selected as one of the UK’s key demonstration projects in offsite construction. It represents an important milestone in the industry’s journey towards modern methods of construction (MMC). The project aims to prove that using standardised, mass-produced components delivers high quality, high performing buildings at better value.

Focusing initially on the healthcare and education sectors, demonstrating how hospitals and schools can be delivered more efficiently, the learnings from Seismic also benefit residential developments and other opportunities. blacc is the lead partner on the Seismic consortium, which also includes offsite manufacturers Elliott Group and the McAvoy Group, Tata Steel, the Manufacturing Technology Centre (MTC), the Active Building Centre (ABC), and the National Composite Centre (NCC).

This project will build upon the success of Seismic I which showed how a standardised light steel frame improved the design and construction of schools. Seismic II will add to this by looking at the building fabric, developing wall, floor, ceiling and roof components that are interoperable with the frame. The ultimate aim is the creation of a ‘kit of parts’ that can be easily configured to suit the specific requirements of the client.

A light steel frame was seen as the essential core building block for this project for several reasons.

Firstly, although the platform is aimed primarily at the volumetric market, it is based on a design for manufacturing and assembly (DfMA) approach where the frame, and other components, could be supplied as individual elements, sub-assemblies or as fully assembled cassettes.

In addition, the steel frame core enables significantly faster and simpler solutions for adapting buildings (upwards or outwards) and for disassembly and reuse over time. Further benefits such as the addition of active building components for energy positive buildings and double-height spaces are also significantly easier to incorporate with a steel-framed system.

BSI LAUNCH NEW HSW REPORT Backed by expertise from global pioneers, the new BSI report provides actionable insight that will help safeguard workers, unlock new commercial opportunities and secure a place in the future of construction.

BSI’s report: ‘The new world of construction: creating a culture of opportunity for health, safety and wellbeing’ - is designed to help create a health, safety and wellbeing (HSW) culture that drives business resilience, brand authority, competitiveness and ultimately, commercial impact.

Download the report at: https://page.bsigroup.com/new-world-ofconstruction-report

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Richard Crosby, Director of blacc, said: “The Seismic system is already proving the benefits of offsite construction in the schools sector and our componentised offsite schools solution has saved the country tens of millions. Unsurprisingly, we are gaining interest from many other sectors too, including housing and healthcare. With this additional investment we are through to a whole new level of productivity, efficiency and materials innovation. Adopting more modern methods of construction will be an essential part of the government meeting its targets to reduce costs and emissions within the sector and can also play its part in delivering better outcomes for building owners, operators and users.”

To find out more go to: https://rlsd.co/p/2iyEFA

INDUSTRY NEWS

DELIVERING TWO COVID-19 MEDICAL FACILITIES IN 14 WEEKS Over the past three months, Clancy has been working with members of the Horizon team to rapidly deliver two major hospital projects in County Limerick in response to the coronavirus pandemic. Within the grounds of University Hospital Limerick, one permanent new block is close to handover consisting of 24 single bedroom isolation units with en-suite bathrooms.

Both projects involve the Horizon offsite structural rapid build steel frame system, which facilitated an earlier start to construction work, a more streamlined process than possible with traditional builds and a considerable reduction in programme time. Given that the hospital remained fully operational throughout the build process, it was necessary to incorporate logistical solutions into the design in order to minimise truck movements and other disruptions to the hospital staff and patients.

Foundation line, point loadings and the structural design of the light steel frame Horizon system commenced on 25 March this year with practical completion on 03 July 2020 .Offsite construction technology experts, Evolusion Innovation were a key driving force in the design process of the light gauge steel frame superstructure and also contributed to Part L compliance.

solution. All parties involved worked seven days a week around the clock to ensure the delivery of this key element of infrastructure was completed rapidly in a time of need.

Construction delivery partners on both of these vital healthcare facility projects included: Clancy Construction, Evolusion Innovation, Reddy Architecture and O’Dwyer Steel.

Early collaboration between all disciplines was critical to the successful delivery of this project. The offsite design approach resulted in an enhanced solution and facilitated the manufacturer of a fast-track steel framing

To find out more go to: https://clancy.ie/

“Frameclad’s growth as a manufacturing company can be attributed largely to its focus on investment in stateof-the-art machinery, modern facilities and in quality personnel, and also having the ability to anticipate what the market requires,” said Mark Munns.

or assembled at the company’s Dudley site where the facilities are set to be extended quickly. Frameclad has also acquired a number of accreditations and industry certifications including NHBC and SCI accreditation and BOPAS for both infill and load-bearing systems.

That investment focus incorporates £2million in machinery – a Howick automated roll-forming machine was an early purchase. It provided capacity, speed and a level of complexity and sophistication of product that placed Frameclad at a distinct advantage.

Frameclad Executive Team: L to R, Paul Winwood Managing Director, Phil Dufty - Operations Director, Mark Munns - Founder & CEO, Martin Jamieson Commercial Director.

SFS STEALING THE ADVANTAGE Acknowledging the opportunities offered by offsite and modular construction has been a key factor in the success story of UK company Frameclad SFS. In establishing itself as a merchant-focused company, Frameclad became an early adopter of light gauge steel framing (LGSF) technology and offsite construction.

The benefits of LGSF in terms of efficiency, speed, low waste and cost savings were recognised from the getgo. For the past six years the company has focused on designing, manufacturing and supplying LGSF components, frames and structures for the construction industry.

It is a move that has been this forward-looking company’s springboard to success. Frameclad has grown tenfold with revenue going from £700,000 to £7.5million in six years, and the company is on a 25% growth trajectory. Founder and Chief Executive Mark Munns assures his company has more than ample capacity to accommodate growth and is well poised to meet increased demand within the industry for the adoption of modern methods of construction.

Very quickly Frameclad recognised and seized the opportunity to commence the manufacture of premade framing packs that can either be supplied loose

To find out more go to: www.frameclad.com

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INDUSTRY NEWS

SIGMAT ANNOUNCE PARTNERSHIP WITH RED SYSTEMS With an ever-growing portfolio spanning residential, leisure and the education sector, Sigmat are now poised to make their mark on the luxury housing market. The firm who has developed three bespoke housing frames, all of which offer high levels of customisation, have appointed RED Systems as their preferred glazing partner.

Sigmat, who have pioneered the development of modern methods of construction over the past twenty years, are now the market leaders in the design, manufacture and installation of light gauge steel frames for the UK construction industry.

The partnership with RED systems coincides with the launch of the firm’s new luxury housing division which has been developed on the back of the company’s success in the residential sector. Sigmat anticipate that demand for houses built using MMC will continue to increase.

Speaking about the teams plans to roll out the new luxury housing models across the UK, Sigmat CEO

NHBC LAUNCHES NEW MMC ACCEPTANCE SERVICE FOR UK CONSTRUCTION INDUSTRY

Mark Eburne said, ‘This partnership represents the culmination of a significant amount of research and development into delivering fully glazed units for both our new luxury home division and existing commercial clients across the UK. We are excited to be able to tap into RED’s expertise as we continue our ongoing programme of research and development and look forward to working with them on a whole range of industry leading initiatives in the coming months.’

RED Systems will be working alongside Sigmat’s in-house design teams to provide factory installed window systems for the new bespoke housing range as well as a number of commercial projects. The team have already created a bespoke bracket to kickstart the project which enables products to be factory assembled.

NHBC Accepts is an all-inclusive, end-to-end service that will help to build confidence in innovative construction and enable MMC systems to be fast-tracked for NHBC warranty.

“All new homes across the UK that are covered

by NHBC’s Buildmark warranty are inspected at key stages during construction by our directly employed and highly skilled team of more than 350 inspectors. An NHBC Accepts certificate is a way of demonstrating that innovative products or systems have already been reviewed thus reducing the risk of delays on-site.

As part of the new service, detailed and robust technical reviews at key stages will result in provision of a certificate (and acceptance for NHBC warranty), usage licence for a bespoke NHBC Accepts logo and website listing.

NHBC has been a long-standing supporter of innovation within construction and their experienced MMC team will be offering a personalised approach via various channels and dedicated touchpoints, providing added value and confidence.

NHBC’s, Innovation Manager, Richard Lankshear (pictured) said: “The case for innovative forms of construction has strengthened and, as housebuilding resumes, the drive to transform construction is accelerated.

NHBC, the leading warranty and insurance provider for new homes in the UK, has launched a new service dedicated to the rapidly growing area of modern methods of construction.

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“We expect to see more innovative construction solutions emerge over coming years and NHBC’s thorough and rigorous approach to new MMC systems will help bring benefits to manufacturers, developers and builders.

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To find out more go to: www.sigmat.co.uk

“NHBC Accepts will play a critical role in ensuring developers, manufacturers, lenders and consumers have faith and confidence in MMC quality as the industry delivers more innovative new homes for the country.”

Chief Executive of Cast Consultancy and the Government's MMC Champion, added: “I welcome the launch of NHBC Accepts. It’s a step forward that sees the UK market leader in warranty and insurance for new homes making its commitment to high quality modern methods of construction clear.”

To find out more go to: www.nhbc.co.uk/accepts

INDUSTRY NEWS

REAPING THE REWARDS OF STRATEGIC INVESTMENT

The last six months have certainly been challenging for everyone. However, during this unprecedented time MetStructures has reported that the business has gone from strength to strength.

Keith Wood, Head of Business Development at MetStructures explained that the firm has secured several sizeable residential and student accommodation projects, saying: “By working collaboratively with our clients’ teams at early design and commercial stages we were able to optimise both the light steel frame and hot rolled podium designs for the projects. We introduced new details that enhanced our system and

accelerated our clients on-site programmes. This presented our clients with both cost and programme efficient solutions.”

from home in this period and we could not be any prouder of them, as the last six months' successes were a result of their dedication.”

MetStructures has invested in their manufacturing, estimating and design capabilities. Whilst it has been a difficult period for the construction industry, this investment has proved successful for them.

Keith Wood added: “Our Directors did not want the company to stand still and be burdened by a possible stagnation due to the COVID-19 crisis. They took this opportunity to progress and invest in our company and indeed, all the companies within our group. They asked us to focus on what would be of benefit to our customers. The majority of our team were working

MetStructures are looking forward to delivering these and further new projects in the near future.

Should you have a project that you would like us to assist you with please contact: keith.wood@metstructures.uk.com or andrew.warren@metstructures.uk.com who will assist with your project.

To find out more go to: www.metstructures.uk.com

Leading Design Consultants for the Light Steel Framing sector CONTACT US

01642 686 556 info@dacs-ltd.com

www.dacs-ltd.com

LSFA DESIGN GUIDE

DRIVING GROWTH AND SPECIFICATION

Whilst some construction materials have had a somewhat chequered history, light steel frame as an advanced, non-combustible and durable technology – has a 30-year track-record of delivering robust buildings that stand the test of time.

Due for publication later this year, the LSFA Design Guide will feature the vast array of benefits light steel frame brings to construction projects, together with an overview of systems and applications as well as technical specification guidance and performance evidence.

The design opportunities this versatile and proven method of construction brings to offsite developments is infinite and the LSFA Design Guide touches on both the practical elements but also the immense possibilities of designing in light steel frame.

THE COLLECTIVE POWER OF THE LIGHT STEEL FRAME ASSOCIATION (LSFA) AND ITS MEMBERS IS DRIVING GROWTH AND SPECIFICATION OF LIGHT STEEL FRAMING SYSTEMS ACROSS ALL CONSTRUCTION SECTORS. THE ASSOCIATION’S FORWARD-THINKING APPROACH UNIFIES CONSTRUCTION PROFESSIONALS ACROSS THE SUPPLY CHAIN AND MEMBERS ARE NOW COLLABORATING TO DEVELOP A DESIGN GUIDE WHICH WILL OFFER IN-DEPTH INSIGHTS FROM THOSE AT THE CUTTING-EDGE OF DESIGNING, ENGINEERING, AND MANUFACTURING IN LIGHT STEEL FRAME. 14

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PERFORMANCE IN CONSTRUCTION Incorporating how systems are installed and how they behave in different situations such as weather events and fire scenarios – performance in construction will provide vital information for designers looking to increase safety and resilience during the construction process. The risk of fire is an area of great concern in building design, but the impact of fire during construction is significantly reduced when using light steel frame when compared to ‘more combustible’ systems. This is further reduced when concrete or screed on steel decks are used rather than timber decks.

PERFORMANCE IN USE Encompassing fire mitigation measures, enhanced acoustics, thermal efficiency, airtightness, energy performance and weathertightness – performance in use advises on how to increase fire safety, building performance and structural strength to alleviate hazards when the building is in use. Building Regulations compliance is a key area for performance in use along with requirements of the warranty provided.

Performance is proven by test evidence and advice will include structural engineering standards with a matrix which lists key elements of Building Regulations with light steel frame credentials against each point.

LSFA DESIGN GUIDE

SUSTAINABILITY Buildings should not only be inherently safe but should also be constructed to last a long time and therefore be inherently sustainable. Buildings are responsible for almost half of the UK’s carbon emissions and around a third of its landfill waste. This means that the UK’s sustainable development targets cannot be met without a major change to the way in which buildings are designed, constructed and operated.

National targets for carbon emission reductions and the drive for buildings that are ‘low carbon’ in operation present a huge challenge to the construction industry – a challenge which the steel construction sector is playing a major part in overcoming.

Steel can be recycled or reused endlessly without detriment to its properties. This unique characteristic gives steel a high value at all stages of its lifecycle. The recovery infrastructure for steel recycling is highly developed and extremely efficient and has been in place for decades. Current recovery rates from demolition sites in the UK are 99% for structural steelwork and 96% for all steel construction products – figures that far exceed those for any other construction material.

Steel’s material properties make it the ultimate sustainable construction material both in terms of its longevity, material properties and enhancing the safety credentials of steel framed buildings. Its superior strength-toweight ratio means a little steel goes a long way, giving architects complete freedom to innovate and create new and exciting buildings. Low and zero carbon buildings and buildings with high BREEAM ratings are readily achievable using steel construction.

infill walling applications. Steel framing systems can be load-bearing, provide infill-walling or/and continuous walling.

Structural panels assembled from cold-formed galvanised steel sections can be used in a wide range of building types including hybrid situations with concrete and other materials.

STEEL FRAMING SYSTEMS Light steel framing may be utilised in the form of panelised or volumetric systems and are typically used for the primary structure of housing and lowto-medium-rise buildings of up to 10 storeys.

Light steel framing and modular constructions are load-bearing systems that are suitable for low, medium and high-rise buildings and renovations such as in rooftop extensions. The use of these forms of construction is closely related to the wider benefits that are offered to the developer and the main contractor. Multi-storey and mixed-use buildings comprising commercial space or car parking at the lower levels with residential units above are all achievable in light steel framing.

Light gauge steel framing can be used for a building's full frame but also for a variety of roofing, modular options and

High levels of thermal insulation and airtightness are achieved with a light steel frame. The lightweight nature

of these systems mean that selfweight can be reduced by over 70% relative to concrete and block-work construction. This results in related savings for foundation loads and sizes.

Steel components can be further preassembled or fabricated into modules either offsite or at a low level. This then reduces the need for working at height, with steel being delivered to site as and when it is required, reducing the need for onsite storage.

WORKING GROUP Mark Jowett – Cogent Consulting Darren Richards – Cogent Consulting Andrew Way – SCI Steve Thompson – EOS Nik Teagle – DACS James Young – Evolusion Innovation David Holmes – Ayrshire Metals Ryan Simmonds – Sigmat Robert Clark – Fusion Building Systems

To register to receive a copy of the LSFA Design Guide email: info@lsf-association.co.uk

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OFFSITE AWARDS BEST USE OF STEEL WINNER

WINNER: FUSION BUILDING SYSTEMS

2020

WINNER BEST USE OF

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STEEL TECHNOLOGY

RECOGNISING THE ADVANCED DESIGN AND MANUFACTURING KNOW-HOW THAT MAKES INSPIRING PROJECTS POSSIBLE - THE OFFSITE CONSTRUCTION AWARDS CELEBRATE EVERY ASPECT OF THE INDUSTRY FROM OUTSTANDING PROJECTS AND MODULAR TECHNOLOGY TO ARCHITECTS WITH IMMENSE VISION AND ENGINEERS WITH STRUCTURAL INGENUITY.

Fusion Buildings Systems picked up the trophy for Best Use of Steel.

The winning project is a benchmark example of how Fusion’s ‘product rather than project’ thinking assisted in the adoption of an integrated supply chain model, to deliver an excellent offsite solution.

UNIVERSITY OF SUSSEX, EAST SLOPES’ RESIDENCES With over 2,000 student bedrooms and a total project value for Balfour Beatty of around £150million, the University of

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Sussex East Slopes Residences is one of the single largest, successful offsite construction projects of its kind ever built in the UK. An early commitment to Fusion’s light steel frame system and breaking the mould with payment in advance, meant Fusion could design and manufacture ahead of time, enabling maximum flexibility on the build programme.

The project was a learning experience for all involved, with productivity improving phase by phase. It was

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the mutual respect however, and partnership spirit adopted by each organisation which ultimately saw this project achieve a successful completion.

Balfour Beatty engaged Fusion Building Systems at the concept stage – some three years before work started on-site.

Interaction started in 2014 and Fusion were awarded ‘preferred bidder’ status in 2015 and then spent the next two years working on design and planning approval, before starting on-site in January 2017.

OFFSITE AWARDS BEST USE OF STEEL WINNER

02 By having this level of engagement the team at Fusion were able to work with the project architects on the specific requirements of the load-bearing light steel frame, fully incorporating them into the building designs to optimise the use of our offsite solution. Sequenced over five phases to deliver 29 blocks in 86 weeks and on a very tight and sloping site – the project required detailed planning for all parties. In order to optimise build speed and reduce site-based risks, Fusion invested in additional storage facilities to provide ‘just in time’ deliveries, and worked with Balfour Beatty on their decision to build a prototype unit on-site, helping identify issues which might not have been clear in the digital environment.

Excellent progress has been made by follow-on trades, reflecting the benefits of early engagement. This project demonstrates that Fusion is a light steel frame specialist who has the experience and capability to deliver projects of this scale, but also positions Balfour Beatty as an innovative, open-minded and adaptable organisation which is working to drive the construction industry forward.

Fusion’s steel frame was used as the superstructure for 29 blocks accommodating 2,100 bedrooms across three, four and five storey units,

encompassing a mix of apartments and terraced townhouses. Delivery required flexibility in design, programme, storage and logistics, with up to five cranes operating at any one time.

With close co-ordination across all teams, Fusions were able to interface with other major components of the building. As part of the concept development, Fusion produced a fullscale mock-up of one of the buildings on their own site as a test piece. A further prototype unit was built in conjunction with Balfour, using an initial design to validate the principles of the build and provide an educational resource for follow-on trades.

When work commenced, BIM was something the construction partners collectively embraced, running a fully PAS 1192 compliant BIM process with Business Collaborator used as the common data environment. Balfour Beatty operated clash detection meetings using Autodesk Navisworks for Structural, MEP and architectural coordination and also used models for activities such as site logistics planning.

Geoff Grant, Project Director for Balfour Beatty UK Construction Services, said: “East Slopes has been a resounding success and for that outcome, we have to thank the fantastic interaction and

collaboration of all trades working on the project. The ability to continuously improve as the build progressed through the numerous blocks benefitted by having Fusion’s light steel frame system at the core. And, while we were all on a learning curve together, it was the communication and mutual respect evident throughout the project teams which meant challenges could be overcome and improvements seamlessly introduced.

“Fusion’s system was the right choice for Sussex and their team had the right personnel for its delivery. I’m extraordinarily proud of what we’ve achieved so far and as Balfour Beatty continues to place investment in offsite methods of construction, I’m confident Fusion will be one of our partners for many years to come.”

For more information visit: www.fusionbuild.co.uk IMAGES 01-02. Fusion’s steel frame was used as the

superstructure for 29 blocks encompassing

a mix of apartments and terraced townhouses.

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OFFSITE AWARDS BEST USE OF STEEL FINALISTS

CELEBRATING THE BEST IN PRECISION LSF BUILDING Sponsored by

DESIGN AND DELIVERY THE OFFSITE AWARDS IS A CELEBRATION OF OUTSTANDING EXAMPLES OF PREFABRICATION AND FACTORY-BASED METHODS THAT INCREASINGLY STRIVE TO DEVELOP A SUSTAINABLE, STREAMLINED AND COST-EFFECTIVE WAY TO DELIVER A BETTER BUILT ENVIRONMENT. The awards showcase innovation, celebrates best practice and highlights manufacturing excellence in this dynamic arena.

There were high-quality submissions across all categories this year and the competition was fierce, particularly in the Best Use of Steel category – finalists included:

AUSTIN-SMITH: LORD: SCHOONER WHARF

• 18,693 cold-rolled steel members totalling 184 tonnes.

• 1,248 hot-rolled steel parts totalling 103 tonnes including large cantilever balconies • 3,488 sheets of decking forming the composite concrete floors • Approximately 70,000 bolts to connect the steel components.

The MetFrame panels were preassembled offsite in Atkin Trade’s Cardiff manufacturing facility. This offsite construction method reduced the site programme which was a major factor in this system being used. An average of five Atkin Trade operatives were required on-site – taking just 21 weeks to install the structure of the sevenstorey apartment block.

PROJECT TEAM Client: Cardiff Community Housing Association

2020

FINALIST Schooner Wharf is a mixed tenure housing scheme commissioned by Cardiff Community Housing Association in a prominent Cardiff Bay waterside location comprising 85 apartments for private sale and 32 social rented homes.

Due to early contractor involvement and applying lessons learnt from a

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QS: RPA previous project, MetFrame’s offsite system was used for the seven-storey apartment block. The design was carried out to BIM Level 2 standard although not a contractual requirement.

This allowed detailed co-ordination with other disciplines. The statistics for the MetFrame structure are impressive:

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Structural Engineer: Blackburn Griffiths (substructure) and Metsec (superstructure) M&E Engineer: ISTL MetFrame Specialist Installer: Atkin Trade Contractor: Morganstone

OFFSITE AWARDS BEST USE OF STEEL FINALISTS

EOS: RIVER STREET TOWER, MANCHESTER

2020

FINALIST River Street Tower Manchester is a £110million development next to Mancunian Way. The scheme encompasses 791 student bedrooms within a 32-storey building and includes a mix of studios and apartments as well as amenity spaces. Designed by award winning architects Simpson Haugh & Partners, the project brings high quality, affordable student accommodation to Manchester. The scheme features amenity space, including shared communal and social areas together with study rooms, presentation and board rooms as well as relaxation areas.

The project creates a visually striking development which delivers outstanding accommodation for students at the heart of the vibrant new community being formed within the Great Jackson Street regeneration area.

The building’s architectural composition relates to the city and local context, set at a scale comparable to their surroundings. The outer elevations comprise a combination of Cor-Ten weathered steel rainscreen cladding panels providing a contextual material relationship with the surrounding built environment. In contrast, the inner courtyard elevations comprise a combination of coloured dark blue back-painted glass rainscreens and metal panels, creating a layered, reflective sequence of surfaces. This development regenerates a previously dilapidated brownfield site, providing much needed accommodation for the student population.

steel frame infill panels. The offsite manufactured pre-assembled panels were pre-boarded in quality-controlled factory conditions using light steel frames from EOS and Weather Defence boarding from Siniat as part of an Etex package. Removing SFS from the critical path through assembled panels, fitted from inside the building, removed the requirement for mast climbers as the installers were tethered to the building’s core to ensure a safe working environment.

PROJECT TEAM Main Contractor: Downing Construction Architect: Simpson Haugh and Partners Structural Engineer: The Alan Johnston Partnership Installer: Alumet

Working with Downing Construction and contractor, Alumet – the structural solution for River Street comprises a main concrete frame with light

Steel Framing Systems Supplier: EOS

With digital technology at our core, combined with a fully non-combustible system, 20 years of experience and more than 50 projects delivered using concrete composite metal decks, we’re working towards a future built with Fusion.

www.fusionbuild.co.uk

MANUFACTURING MEMBER

25+

2,000+

3,000+

4,000+

12,000+

schools

care homes

houses

apartments

student beds

OFFSITE AWARDS BEST USE OF STEEL FINALISTS

HADLEY STEEL FRAMING AND SWINHAY: LYDSTEP TERRACE, BRISTOL

2020

FINALIST Located on the south bank of the River Avon near Bristol, Lydstep Terrace is a development of nine family townhouses, each has been designed to provide character with a modern

approach to family living. This project was within a re-development site in a highly populated area of Bristol in very close proximity to neighbouring properties on three sides and a park situated opposite. Ensuring positive relationships with local residents was a high priority and key factor for the developers RBH Properties, main contractor Swinhay and Hadley Group.

Using a number of products in Hadley Steel Framing's offsite suite of products, the entire frame structure was designed, cold roll formed to shape, length and individually panelised to meet bespoke requirements. It was also weather protect boarded using British Gypsum’s Glasrock X sheathing board where needed. All components seamlessly integrated to form the superstructure.

The cold roll formed components compliment where required using a minimal quantity of hot rolled columns and connection details.

2020

FINALIST

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PROJECT TEAM Architect: Willmore Iles Developer: Swinhay Steel Framing System Supplier: Hadley Steel Framing

Despite the normal challenges associated with such a large project, the holistic approach was invaluable in mitigating any emerging problems.

Sigmat designed the project and completed the technical drawings ahead of manufacturing and assembling panels prior to final frame erection at site. Their innovative ‘vertical’ approach means they were able to respond to any on-site challenges rapidly, always ensuring the agreed timescales and budget were maintained. Invariably, Sigmat exceeded expectations with quicker finish times and higher than expected savings. Working collaboratively with the client to achieve on-time completion and take advantage of the benefits of light gauge steel frame.

SIGMAT: WINDMILL HILL, BIRMINGHAM

Located in central Birmingham this residential complex with 304 one, two and three bed apartments were delivered by Sigmat. Working collaboratively with Galliford Try and engaging early in the design process ensured the main contractor could take advantage of the benefits the light steel framing system provides. Specifically, with programme surety, improved weather protection and increased

The system that was used in this particular application to deliver this scheme was Hadley Steel Framing 100mm light gauge panelised bolted steel frame system, with 150mm deep concrete composite floors. This scheme also had a requirement for a Mansard Roof and concrete tread infill steel stairs, steel joists, and hot rolled balconies integrated with the superstructure. The adaptable steel framing system (SFS) was delivered and installed easily on-site, overcoming the access challenges, and was used for some of the developments most critical components.

structural efficiency. Engaging in Sigmat’s four-step process from design and detail, to manufacturing and panel assembly, then installation on-site in line with a staged build sequence.

Sigmat’s structural frame consisted of load-bearing external and internal wall panels, support beams, composite concrete metal deck floors and steel stairs with CP board tread inserts.

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PROJECT TEAM Installer: Exact Framing Solutions Main Contractor: Galliford Try Developers: Court Collaboration and Top Capital Group Steel Framing Systems Supplier: Sigmat

OFFSITE AWARDS BEST USE OF STEEL FINALISTS

ADVANCED OFFSITE MANUFACTURING Light steel frame is a fundamentally important material in the offsite construction portfolio and is used for a wide range of building types and applications. Advanced manufacturing processes have now elevated steel framing systems to the forefront of fast-track, sustainable and high-quality construction. Manufacture in controlled factory environments enables repeat quality every time and eradicates the risk of on-site variability, delivering more predictable outcomes.

Courtesy of EOS

steel framing systems reduce the impact on the environment and offers construction solutions to meet challenging targets.

Time is a critical factor in construction.

Offsite projects can be delivered in less than half the time of traditional methods, radically reducing build schedules, leading to less time on-site and ultimately, a faster return on investment.

With stringent legislation to reduce carbon emissions in the drive to minimise climate change - light

Light steel frame provides a lower cost option, whilst maintaining superior quality. Cost savings are achieved due to the speed of construction and resource efficiencies on-site. Steel is unaffected by shrinkage, resulting in dramatically reduced repair costs after completion down the line.

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CASE STUDY

SANDGATE PAVILIONS PRESTIGIOUS RESIDENTIAL DEVELOPMENT SANDGATE PAVILIONS IS AN EXCLUSIVE £10MILLION RESIDENTIAL DEVELOPMENT IN KENT, FEATURING 36 HIGH-END CONTEMPORARY APARTMENTS ACROSS THREE MEDIUM-RISE UNITS SET WITHIN BEAUTIFUL SURROUNDINGS, OVERLOOKING THE ENGLISH CHANNEL.

Private contractor Sunningdale Developments were keen to engage a light steel frame manufacturer who would work collaboratively with their team from concept to completion and provide a high specification system to reflect this prestigious project.

With over 100 years’ experience and outstanding reputation, Ayrshire Metals were appointed to design, engineer and supply 70T of ASF infill panels as well as the loadbearing structure for the top floor of all three apartment blocks.

Ayrshire carried out initial design and feasibility studies and design calculations, utilising their in-house engineers and CAD team. The steel was then manufactured at their advanced manufacturing facility in Daventry, Northamptonshire.

Ayrshire’s specification team attended project meetings from design through to install stages, ensuring continuity, consistent customer service and smooth project delivery.

This collaborative approach ultimately helped to reduce lead times and cost for the client resulting in a successful partnership.

Through efficient design and engineering, Ayrshire were able to reduce the amount of hot rolled steel and concrete required and engineer bespoke jambs to negate the requirement for hot rolled wind posts.

With 100 years of experience, the Ayrshire Group can trace its roots back to 1819, when it was a builder of ships. During the 1930's the company diversified into the cold roll forming of steel sections and this modern method

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of producing lightweight but strong profiles breathed new life into the company.

The Ayrshire group operates from across three sites in the UK, with its headquarters based in Daventry.

The company's mission to provide 'complete customer satisfaction' is underlined by ISO9001 accreditation standards.

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

ADVERTORIAL

BSI is delighted to have launched a brand-new report: ‘The new world of construction: creating a culture of opportunity for health, safety and wellbeing’ – designed to offer actionable insight that will help safeguard workers, unlock new commercial opportunities and secure your place in the future of construction.

Readers can explore three core principles professionals need to transform their health, safety and wellbeing including:

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CULTURE OF CHANGE • How a mindset of prevention and proactiveness paired with a standards-based approach to HSW can boost organizational resilience and competitiveness

NEW COMMERCIAL OPPORTUNITIES? NOW MORE THAN EVER, THE IMPACT OF THE CONSTRUCTION INDUSTRY’S AGING WORKFORCE, INTENSIFYING MATERIAL COSTS, SUSTAINABILITY PRESSURES AND SLOW DIGITALIZATION IS BEING FELT BY ORGANIZATIONS.

With international emergencies and pandemics like COVID-19 and global warming reshaping the way the industry operates, it has never been more important to strengthen organizational resilience and support worker’s health, safety and wellbeing (HSW).

“Globally, there are around 340 million occupational accidents and 160 million victims of work-related diseases each year. This accounts for almost 4% of the worlds GDP, or $3.2 trillion.” – ILO.

In the race to protect their workers from today’s evolving risks and hazards, and to enhance their operational agility, organizations across the globe are taking steps to create a safer, more people-centric construction industry.

Leading organizations have begun to do this by connecting their HSW initiatives with wider business strategies. Not only are these strategies helping them safeguard and prioritise their workers, but it is unlocking new commercial opportunities – and this is just the beginning.

PRIORITISING PEOPLE • How prioritising the wellbeing and equality of workers can improve workforce productivity, agility and build trust STRATEGIC DIGITALIZATION • How investing in the right technology will not only protect workers but will deliver long-term commercial success.

Backed by expertise from global health, safety and wellbeing pioneers within the construction industry, this report also includes the opportunity to put your strategy to the test. Access the HSW standards checklist, and take the BSI quiz to see if your organization has the resilience, agility and culture to not only protect workers, but create new commercial opportunities from your health, safety and wellbeing programme.

Download your copy today and secure your place in the future of construction with a HSW culture that drives business resilience, brand authority, competitiveness and ultimately, commercial impact.

Download now: https://page.bsigroup.com/newworld-of-construction-report

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he

SHAPING THE FUTURE IN METAL

Hadley Steel Framing provides high quality, light gauge galvanised steel structural framing systems for use in a wide range of applications across the construction industry.

Hadley Steel Framing has proven experience in understanding complex engineering structures and provides full design, manufacture and installation packages.

We take complete control, project managing every aspect. This is why our clients appoint us and retain our services time and time again. Achieving fast-track construction schedules - here we define our supportive services, including full ownership of the process, to demonstrate what we can deliver!

HANDOVER At the end of every project there is a comprehensive handover process encompassing final ‘as built’ drawings, Q&A documents, detailed warranties, all operating and maintenance information together with a forthright 360 degree review of the design, manufacturing and installation programme which also highlights where improvements can be made in future projects.

CONTROL 8 Hadley take complete ownership and management of the project - from engineering and manufacturing right through to onsite installation by our specialist teams which even includes cranage, AP and slingers within our inclusive packages. Via Trimble Fieldview we track and monitor every aspect – taking complete control.

MANUFACTURING

7

Our unparalleled rollforming expertise is underpinned by the manufacture of all panelised systems and components within the same advanced factory facility. This ensures rapid and efficient builds with accuracy and controls built in at each stage of the process. We optimise our own offsite manufactured sequence, bringing all elements together to improve your project delivery - the true definition of Modern Methods of Construction.

ENGINEERING 6

t +44 (0) 121 555 1300

Hadley maintain vertically integrated processes – controlling and optimising every aspect. All detailing takes place within the Group to ensure alignment with the original intent. We have the expertise and ability to scope, design, detail, verify, validate and deliver a fully engineered steel framing system.

e ask.hadley@hadleygroup.com www.hadleygroup.com

14 WEEKS

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Your Trusted Steel Framing Delivery Partner Taking Complete Control 1

EARLY ENGAGEMENT Crucial to the success of all offsite construction projects, engagement from the initial stages facilitates an integrated design where for example, facades, windows, balconies, entrances and roof structures can be incorporated into the engineering calculations and design of the structural steel framing system. Our expert team ensure we add efficiency and structure to the process right from the outset.

TENDER STAGE

2

Full collaborative working at the tender stage maximises design, materials and manufacturing efficiencies. Layouts and sequencing can be optimised by developing a full understanding of our client’s requirements – to ultimately achieve vast programme and cost benefits. Our early engagement ensures no unwelcome surprises.

3

CONTRACT AWARDED Now we are officially part of the team. We grow our established links to offer commercial, design and engineering support. Through close collaboration we work as a delivery partner to your team – managing the entire process from the early design stages right through to the project completion.

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PROCUREMENT Hadley Group is the UK’s largest procurer of pre-galvanised steel – we have significant capability and capacity to achieve even the largest and toughest build requirements. Included within this manufacturing scope are the stairs and all complementary works.

CONTINUITY Offering total synergy and continuity – the same Hadley team, the same communication channels, the same plan, the same detailed approach – will be maintained throughout the design, manufacturing and installation process. Our teams will oversee the entire process through to issue of our warranty.

MANUFACTURING MEMBER

PUBLICLY AVAILABLE SPECIFICATION

MOVING TOWARDS A PRODUCT-ORIENTED APPROACH

01

HTA IS A PRACTICE OF AROUND 200 ARCHITECTS, PLANNERS, SUSTAINABILITY SPECIALISTS AND RESEARCHERS, WITH A FOCUS ON CREATING GREAT RESIDENTIAL PLACES AND A 50-YEAR TRACK RECORD IN THE DESIGN AND DELIVERY OF BETTER HOUSING. SUSTAINABLE FUTURES PARTNER, RORY BERGIN SHARES A DESIGNER’S PERSPECTIVE AND CALLS FOR MORE INVOLVEMENT FROM LIGHT STEEL FRAME MANUFACTURERS TO SUPPORT PUBLICLY AVAILABLE SPECIFICATION (PAS) FOR LARGE SCALE PREFABRICATION. We have a long history of working with steel, both full volumetric systems and light gauge steel (LGS) panels.

Even traditionally realised buildings tend to have LGS internal walls and partitions, although many of those are not prefabricated due to the difficulty of concrete framing to maintain tight tolerances. An area where we see progress is the ability of framing companies to bring fabrication systems to site and to prefabricate LGS wall panels on-site or close to site which can be fitted as fill walls. The sooner our projects can have an external envelope,

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the sooner follow-on trades can get to work on servicing and finishes.

Many of our medium-rise buildings have been constructed fully in LGS panels where the issues of interaction with traditional construction are lessened. Contractor clients find that having a single sub-contractor deliver the entire structure and all the internal partitions under a single contract simplifies their procurement and speeds up the delivery of the project.

In some cases, where the insulation is included in the LGS system, it brings

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added benefits in terms of delivering a high-performance envelope. Projects such as student accommodation, hotels and build-to-rent all derive a lot of benefit from faster construction as the project finances depend on the building being delivered on time. A saving on the programme also means savings on borrowing costs, and earlier rental returns which helps to pay back the initial investment.

The dimensional accuracy of steel framed construction also means that it is easier to integrate with

PUBLICLY AVAILABLE SPECIFICATION

02 other prefabricated systems such as bathroom pods and prefabricated utility cupboards or prefabricated risers. The tight tolerances used in the manufacturing process for all of these means it is easier to co-ordinate them with a steel framed system than with a traditional RC frame. As the appetite for this approach grows in the industry, we will see more integration and co-operation between LGS manufacturers and other manufacturers to supply more joined-up solutions, by supplying wall panels pre-wired, with windows in the external wall, and cores and risers integrated into the structure.

The issues around design and construction quality highlighted by the Grenfell tragedy demonstrated that we cannot continue to function the way we have been, avoiding risk and responsibility and passing it down the food chain to the lowest subcontractor. Manufacturers need to take responsibility for their products,

and to work with other manufacturers to develop shared systems that can be relied upon and which come with certification and warranties. We see the industry moving towards a more product-oriented approach where there is agreement among the industry that we need more certainty of performance in exchange for less flexibility in products. As designers, we want to be able to deliver buildings which can be relied upon to perform in the way they were intended. We see the path to that is to be found by working more closely with manufacturers.

As part of our approach we aim to create a PAS for large scale prefabrication. We will work with BSI to create it and to do it we need the support of the industry. BSI will manage the process as usual, and we will provide the technical team behind it, but we need support from industry to make it happen. We think that the LGS sector will benefit greatly from the

03 confidence that a PAS brings, and we would like to hear from any of you that would like to contribute your time and expertise.

For more information visit: www.hta.co.uk IMAGES 01.

Cane Hill. Credit: HTA Design LLP,

Photographer: Richard Downer 02-03. Oakridge Village. Credit: HTA Design LLP

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CASE STUDY

SCHOONER WHARF ACHIEVING ENHANCED PERFORMANCE

01

IN RESPONSE TO AFFORDABLE HOUSING PRIORITY NEEDS, AUSTIN-SMITH:LORD WERE COMMISSIONED BY CARDIFF COMMUNITY HOUSING ASSOCIATION TO DESIGN A NEWBUILD MIXED TENURE HOUSING DEVELOPMENT IN A PROMINENT WATERSIDE LOCATION IN CARDIFF BAY. Contemporary in design, the scheme utilises a combination of traditional and innovative materials. This creates a development that has a readily identifiable and fresh, modern character whilst also providing the sense of solidity and reassurance that comes from the recognisable layout and scale.

By adopting passive solar design principles, Schooner Wharf is built to high environmental performance standards using Metsec’s MetFrame system which will reduce in-use energy costs. Fuel poverty is addressed through a highly efficient building fabric and energy strategy including use of renewables. MetFrame was chosen as part of the wider environmental benefits it provides in addition to its

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cost and speed advantages. The offsite construction and detailed co-ordination prior to fabrication meant there was effectively zero waste and a low carbon footprint for the structural frame.

The apartment block is constructed using light gauge steel offsite manufacture whilst the houses utilise timber frame kits. The Metsec loadbearing walls consist of 100mm wide vertical C section studs at max 600mm centres. Metsec components are rolled from pre-galvanised steel. All sections are cut to length and have holes punched to allow bolted connections.

Walls are detailed in panels typically up to eight metres long by one storey tall that are pre-assembled offsite by Atkin Trade Specialists. The external

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face of the MetFrame external panels is clad with a 12mm cement particle board over which the external insulation is installed. Structural steelwork is integrated into the MetFrame system where required.

Cantilever balconies and projecting bays are constructed from a hot rolled steel frame with galvanised finish and thermally broken from the MetFrame structure. These are installed when their supporting external walls are installed.

The balconies are designed to allow a lightweight floor to be installed by others. Stairs are offsite assembled/ fully-welded units with in-situ concrete filled steel treads. They are fitted as each storey of MetFrame is installed.

Lift shafts are included in the MetFrame.

CASE STUDY

They have horizontal Metstrut channels bolted into the two side walls of the shafts for the lift manufacturer to fix to.

Roof systems use Metsec joists typically 200mm deep at 600mm centres.

This project follows on from a previous six-storey apartment block, delivered by the same contractor and design team, which was completed eight weeks ahead of programme by using the same MetFrame system. Lessons learnt from the previous project including a knowledge transfer partnership (KTP) with Cardiff Met University led to improved thermal performance of construction interfaces. The findings of this KTP led to better interface details for Schooner Wharf which in turn led to enhanced thermal efficiency and performance.

The speed of erection led to cost savings and allowed other trades to commence work simultaneously. An average of five Atkin Trade operatives was required on-site taking just 21 weeks to install the structure of the

02 seven-storey apartment block. Given the site was constricted between a quiet residential development and offices, the speed of construction and offsite processes minimised noise, disturbance and disruption to the local community.

Offsite construction generates up to 90% less waste than site-based building methods and achieves up to 90% fewer vehicle movements on-site, compared to a traditional construction project – reducing noise, dust, congestion and carbon emissions. This project pushed

the limits of the MetFrame system and required thinking outside the box to overcome the technical challenges of the design.

For more information visit: www.austinsmithlord.com IMAGES 01-02. The apartment block is constructed using a

well-understood offsite light gauge steel system.

Courtesy Austin-Smith:Lord/Metsec

Your partner in delivering a

LIGHT GAUGE STEEL FRAME to meet your project requirements

• MetStructures light gauge steel framing, NHBC and SCI approved to 15 storeys • 100mm external and internal LGSF walls • MetFloor composite metal decking and concrete • Fully finished balconies • Hot rolled steel podium structures • MetSafe accredited temporary edge protection system.

• All elements designed, coordinated, supplied and installed on site.

Should you have a project that you would like us to assist you with please contact: keith.wood@metstructures.uk.com or andrew.warren@metstructures.uk.com who will assist with your project.

Your exact project requirements Met MetStructures LIGHT GAUGE STEEL FRAMING SPECIALISTS

t: 0121 380 1603 | e: info@metstructures.uk.com

www.metstructures.uk.com

CASE STUDY

WINDMILL HILL DELIVERING STRUCTURAL EFFICIENCY

01

AFTER GALLIFORD TRY WERE APPOINTED AS THE PREFERRED DEVELOPER FOR WINDMILL HILL, SIGMAT WERE SELECTED TO PROVIDE THE LIGHT GAUGE STRUCTURAL STEEL FRAMING SYSTEM FOR THE UPPER RESIDENTIAL LEVELS OF THE 22,735M2 BIRMINGHAM SCHEME. Providing a total of 304 one, two and three-bedroom apartments across three blocks – the structural frame incorporates load-bearing external and internal wall panels, support beams, composite concrete metal deck floors and steel stairs with cement particle board tread inserts.

The Sigmat system removed the need for secondary infill steel to the external walls which were pre-panelised offsite including the formation of all structural openings resulting in the facade being removed from the critical path of the

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build programme so internal trades could commence sooner and water ingress was diminished.

All the structural walls are a common width of 100mm and positioned on the wall line of the architectural intent negating the requirement for bulky, obtrusive boxing out around columns, giving a consistent internal finish in each unit. Another consideration was to provide the corridor wall as part of the frame – this had two advantages.

It could span the composite concrete metal deck perpendicular to the

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corridor wall eliminating the need for downstand beams across the corridors and risers. It also reduced the span of the trimming beams within the residential apartments to the extent that Sigmat could employ the use of their patented 'top hat' section to act as a beam.

Sigmat steel frame structures use significantly less construction material than that of a reinforced concrete which unlike steel, also requires continuous maintenance and repairs.

Furthermore, a significant percentage

CASE STUDY

02 of the steel used comes from recycled materials and is therefore more sustainable and cost-effective than concrete alternatives.

Specifying a light steel framing system offered time savings with the structure being completed in a shorter duration.

Sigmat’s designs are also based on end to end steel connections which means that they achieve an increase of circa 17.8% in structural efficiency when compared to many key competitors.

The Sigmat system reduced the carbon footprint of the development during construction and with a high-performance energy rating, throughout the in-use lifecycle. The offsite approach decreased the number of journeys to site and reduced the size of loads by more than 70% when compared with more traditional concrete and block-work methods.

Waste was virtually eliminated on site through the use of prefabricated light steel and modular components.

A key benefit of the Sigmat system is its ability to be repurposed – all steel components can be reused and recycled, even the concrete in the floor slabs can be crushed and used again as an aggregate in lean mix concrete.

Productivity was vastly improved resulting in the speed of construction being increased by more than 30%. The offsite manufactured steel technology also vastly reduced on-site operatives

03 with a maximum of 12 personnel required to install the frame at peak times.

As the initial concept for the structure was a concrete frame, Sigmat helped guide the architects and engineers to develop a greater understanding and the system was integrated into the existing layout with minimal impact on the design.

Sigmat can install up to 1100m² of light gauge steel with concrete floors included within a two-week period with pre-formed service openings for air conditioning, pipes, ventilation and

electrics included. The nature of offsite in a highly controlled environment means on-site health and safety is enhanced and the risk of injury from ‘early stage’ construction is removed or even eradicated.

For more information visit: www.sigmat.co.uk IMAGES 01-03.

Offsite manufactured steel technology improved productivity, increased speed of construction and reduced the required number of on-site operatives.

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ADVERTORIAL

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FROM ESTIMATING TO ERECTION The STRUMIS software program automatically tracks all associated project costs – from tender stage right through to completion and hand-over – enabling real-time budget comparisons from estimate and tendering to actual project costs including all employee and process time along with steel and plant hire, variations to contract, change order management and contract invoicing.

COMMITMENT TO EXCELLENCE Adopting STRUMIS is acknowledged as a commitment to business excellence which will attract new customers while also improving existing customer satisfaction.

STEEL FABRICATION AND CURRENT CONSTRUCTION BEST PRACTICE CALL FOR THE UTILISATION OF INNOVATIVE TECHNOLOGY TO STAY AHEAD OF THE CURVE AND REMAIN BOTH RELEVANT AND PROFITABLE IN AN EVER MORE DYNAMIC INDUSTRY.

The application of Material Requirements Planning (MRP) software in the steel fabrication and construction processes is no longer an obscure concept but more a vital standard management practice. Software systems, such as STRUMIS serve the largest and smallest fabricators and construction firms across numerous market sectors which enables them to successfully control their business and

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mitigate risk – ensuring transparency throughout each department and safeguarding the management of resources effectively.

STRUMIS bi-directional project links with partner systems like 3D CAD programs such as Tekla, Advance Steel and many others, empowering quick and informed decisions to minimise cost and disruption, by seeing

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STRUMIS LTD are a UK-based privately owned company in Derby with a long history serving the steel fabrication and construction industries. With more than 30 years of experience, and 20,000 users in over 65 countries globally, STRUMIS solutions are well placed to help drive efficiency, improve productivity, enable 100% traceability and ultimately – assist with improved profitability.

For more information on how STRUMIS can help your steel fabrication business please visit: www.strumis.com or contact: sales@strumis.com or telephone: 01332 545800

NOW INTRODUCING PROGRESS INVOICING SAVING YOU TIME AND MONEY A WORLD LEADING STEEL FABRICATION MANAGEMENT INFORMATION SOFTWARE SUITE, USED WORLDWIDE TO REDUCE COSTS WHILE MAXIMISING PRODUCTIVITY AND INCREASING PROFITABILITY. NEW FEATURES INCLUDE: ADDITIONAL ESTIMATING FEATURES SMARTER VARIATIONS LOGIC ENHANCED NESTING ENGINE GLOBAL DOCUMENT PRINT FUNCTION APPLICATION FOR PAYMENT FEATURE

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SALES@STRUMIS.COM | 01332 545800 | WWW.STRUMIS.COM SOFTWARE BY STRUMIS LTD. PART OF THE GLOBAL RDS GROUP

DIGITAL ENGINEERING

MODERN ENGINEERED SOFTWARE SOLUTIONS LIGHT GAUGE STEEL ADD IN FOR TEDDS LIGHT STEEL FRAME (LFS) LIKE MANY MODERN METHODS OF CONSTRUCTION IS BECOMING LESS OF A NICHE MARKET AND A REAL GROWTH AREA WITHIN THE CONSTRUCTION SECTOR. MODERN ENGINEERED SOFTWARE SOLUTIONS WAS STARTED TO FILL A VOID IN THE MARKETPLACE FOR ENGINEERS WANTING TO DESIGN IN LIGHT STEEL FRAME. The add in for Tekla Tedds enhances LSF capabilities within the existing portfolio and improves the easy-to-use structural analysis software. The add in is available as a standalone version with all manufacturers data available or as a bespoke version tailored to each company.

Users enter data such as span, joist centres and loads applied, then select profiles from over thirty manufacturers.

Over the years more features have been added – the software now includes: • Pitched Roofs in LSF using the 2D Analysis engine built into Tedds • Members are rotatable on plan – for roofs, C section joists and lattice trusses • Floors, roofs and trimmers (single members) can be pitched up to 90o • Studs as part of a wall system or a single stud • Lintels can be designed as lattices or compound C sections in load-bearing walls • Facade designs comply with ED019 and FIS guidance • Racking, sliding and overturning of building • Offers weight per square metre or linear metre as appropriate for pricing • Provides all that is needed to design multi-storey buildings in hours.

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Users can switch within calculations between British and European Standards enabling rapid comparison of results. The latest software provides calculations to both British Standards (BS 5950-5) and Euro Codes (EN1991-1-3). Given that wind is one of the critical design factors for roofs and walls, a bespoke version of Breve that links to the existing Tekla Tedds wind modules for BS 6399-2 and EN1991-1-4:2005+A1:2010 has been developed. The software uses the Nasa Topographical database in Breve to populate the site-specific details for wind analysis to the nearest one hundred metres, as opposed to the nearest town as the standard data contained in Tedds.

Included with the latest version of the software is bespoke fire rating calculation based on test data and design loads as well as duo-pitched roofs and self-weight of all members.

Future updates include multi-span beams for joists and trimmers and improved lintel options. On average an update is issued every two months.

Working with Vertex UK a two-way link between Vertex and Tedds has also been developed using the built in Excel export and import tools. It means that users can fill in one form in Tedds and within thirty minutes be rolling metal

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to assemble into a bespoke two-storey house.

In addition, Modern Engineered Software Solutions in partnership with sister company MMCEngineer, are now offering monthly training sessions on the design of light steel frame using the add in, as well as producing research with a number of universities, including Northumbria and Leeds Universities.

For more information visit: www.mess.uk.com or email: steve@mess.uk.com

ADVERTORIAL

compatible hard hats fitted with the Mira AR technology to new customers currently.

As Nick points out: “Given we have such a diverse range of tailor-made machines and technology going into the market, we needed something that gave us a truly engaging experience. We spent a lot of time experimenting with various solutions. The Mira system proved to be the best hands-free option available.

We’ve live-tested it on multiple sites now, and it’s been well received.”

HOWICK ADOPTING AR TO GIVE CUSTOMERS AN EDGE AS A NEW ZEALAND COMPANY WITH A REPUTATION FOR INNOVATING IN LIGHT GAUGE STEEL IN THE CONSTRUCTION SPACE, HOWICK IS CONTINUING TO EVOLVE ITS OFFERING WITH SMART TECHNOLOGY. With a diverse range of Howick machines used internationally, it is vital that support is never a world away – even in a pandemic. As a result, the company has now turned the current restrictions on global travel into an opportunity to advance its offering.

HOWICK SUPPORT CLOSE AT HAND As Nick Coubray, Howick’s CEO puts it: “We place a huge emphasis on premium support for our customers, so we wanted to find a way to not just emulate our pre COVID-19 service levels, but take them up a notch too.”

This has led the company to adopt Augmented Reality (AR) technology, with the Mira ‘wearable workflow platform’, as the enabler. Mira was chosen for its ease of use, as well as its potential for future applications in quality control, compliance and workflow authoring.

The system creates a virtual ‘in-person experience’, so Howick’s team can guide customers through engineering support requirements, remote commissioning and training needs. Howick is rolling out the PPE

TAILOR-MADE CAPABILITY Howick has a global reputation for creating innovative solutions and manufacturing precision systems tailored to specific customer needs.

This drive to innovate continued this year with the launch of the X-TENDA 3600. The result of a collaboration with a contractor who was trying to solve a specific infill framing challenge, the machine produces extendable frames that expand outwards and upwards to fit the most uneven of interior spaces. The machine promises to be a game-changer; dramatically reducing installation times, making installation far easier and reducing wastage.

100% MADE BY HOWICK IN NZ Howick backs up the quality of its technology with unique industryleading guarantees. This is possible because the company’s steel framing systems are made on-site in New Zealand with locally sourced components, allowing complete oversight of its supply chain, systems and processes. What is more, all major componentry used in the Howick FRAMA machines is made in-house.

This commitment to uncompromising quality assures reliability and provides a true competitive advantage to Howick’s global customer base.

To discover more about Howick systems or to discuss any specialist applications you are considering, email: deon@howickltd.com

For more information visit: www.howickltd.com

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SUSTAINABILITY

THE MAGNIFICENT 7 REASONS WHY STEEL IS SUSTAINABLE

SUSTAINABILITY MEGATRENDS ARE SHAPING OUR WORLD. IN PARTICULAR CLIMATE CHANGE, SCARCITY OF RESOURCES, AND DEMOGRAPHIC SHIFTS. THIS IS FEEDING INTO SOCIETAL EXPECTATIONS WHICH IN TURN DRIVES POLICY FRAMEWORKS AND LEGISLATION.

So what does this mean for the construction industry?

The construction industry is responsible for a significant amount of resource use (both materials and energy consumption) and waste. The pressure to become more sustainable is considerable and industries are working hard to reduce resource use, decrease waste and become more sustainable.

Understanding how building materials perform in use, and what happens to them at end-of-life, has an important role to play in achieving a more sustainable construction environment.

Steel, as a building material, has many attributes that are very well suited to achieving this ambition and here are just some of the reasons why:

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1. Steel can reduce resource use for a given building design Improvements in the understanding of the use of steel, combined with improvements in steel processing (including micro casting – producing just 20 kilograms of steel) has meant the ability to efficiently develop higher strength and higher performing steels.

The development of higher strength steels means that we can build with less steel. Less steel means lower upfront carbon, but not just from the steel itself, also from reductions in the transport weight, construction and foundation weight. In general, the use of a steel framed building utilises less space and less foundations when compared with an equivalent concrete design, so any further reductions from weight savings is a win-win.

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2. Steel is extremely durable and long lasting – maximising its use as a resource An important but often underestimated attribute - but building with a material that requires little or zero maintenance, and can meet design life requirements into three figures, equates to a resource that is being maximised. If we take weathering steel for example, we have a material that can last 120 years or more with little or no maintenance.

Combining this capability with the adaptability of steel and you have a material that will last a very long time and then, at the end of its life, can be put to another use.

3. Steel is well suited to the circular economy The durability and adaptability of steel makes it very well suited to the circular economy. If we define the circular economy as ‘reducing resource use, and reducing the waste associated with that resource use’ then we have already demonstrated above that we can do more, with less steel, than ever before, but this durability and adaptability also allows us to: a. Modify and adapt existing buildings, to easily allow business expansion or change of building use. b. Reuse steel at the end of its use; the inherent ability of steel to be demounted, though simple product design, makes the deconstruction and reuse of steel in the built environment a potentially extremely efficient process. The construction industry is not yet ready, at scale, for this, but with co-ordination on standardisation of products, consistent and fully adopted data protocols and construction techniques, then steel reuse can become a key driver of improved built environment sustainable performance. c. Steel can be deconstructed and ‘remanufactured’ for another purpose, unleashing a further life for the resource. d. Finally, when steel cannot be reused or repurposed then it has a real trick up its sleeve – it can be (and is 99% likely to be)

SUSTAINABILITY

recycled to become another steel product. A key to driving the circular economy is to retain value in resources for as long as possible. The steel scrap market is one such mechanism for steel that almost guarantees that if steel can be recycled it will be.

4. Steel manufacturing is continuously improving The energy used, and the CO2 intensity in the manufacture of steel in Europe, has reduced on average around 1%1 per year from the turn of this century, and the energy required to produce a tonne of steel in the UK has reduced by some 40%2 since the mid-1970’s. And we are now approaching theoretical limits on steel making meaning that breakthrough technology will be essential to maintain these trends, which leads us to…

5. Steel is well suited to break through sustainable technologies Tata Steel are the owners of HIsarna, a breakthough technology which has the capability to lower future steel making CO2 intensity by up to 50%. Combined with carbon capture and storage this may increase to 80%. Work to further develop HIsarna continues and this work is in the context of Tata Steel’s confirmed ambition to be carbon neutral steel making in 2050.

6. Steel in construction minimises waste Whilst steel manufacturing is extremely circular, with many of the by-products of the steel making process being utilised in other processes or industries – steel as a construction material also contributes to reduced waste.

Steel is extremely well suited to offsite construction and modular methods of construction by its very nature.

Both its formability and processing characteristics mean that what waste is generated becomes the input to further steel making (recycling). Such characteristics contribute to reduced construction time and increased construction efficiency.

7. Steel’s contribution to the built environment Probably the most important of our magnificent seven reasons; it is not only

steel as a material that can contribute to a more sustainable construction industry but the products that are produced from steel, during their lifetime, can make our building assets more efficient, more effective (as ideal living and working spaces) and more sustainable. From the insulated and airtight panels that Tata Steel produce (reducing energy consumption), to the integrated renewable energy generators that will deliver energy positive buildings, steel has an important role to play in our ambition for a more sustainable built environment.

At Tata Steel, we believe that only by taking a complete lifecycle perspective can we both optimise the use of the world’s limited resources and reduce waste. Circular economic thinking is a key part of that solution, from initial product design to end-of-life and beyond, focusing on just the impact of a material at its conception fails to take the impact of a material on the future and the unintended consequences that this brings with it.

From these seven reasons, it is clear to see that steel has an important role, and capability, in delivering a circular economic and sustainable future for our built environment.

For more information visit: www.tatasteelconstruction.com

1 2

Derived from World Steel data.

Derived from UK Steel data

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OFFSITE PROGRESSION

THE TRANSITION FROM MINORITY TO MAINSTREAM

WITH DECADES OF EXPERIENCE TO DRAW ON – COGENT CONSULTING IS ENGAGED ADVISING ON A WIDE RANGE OF OFFSITE DELIVERY ISSUES ACROSS THE UK AND OVERSEAS. HERE MANAGING DIRECTOR DARREN RICHARDS, SHARES HIS PERSPECTIVE ON THE PROGRESSION WITHIN THE SECTOR OVER THE PAST FIVE-YEARS TO THE PRESENT STATE OF THIS EVOLVING MARKET.

Whilst the industry has made significant progress there is still someway to go before offsite technology is considered mainstream. An abundance of manufacturers in the offsite arena are still not embracing digital engineering and design for manufacture and assembly (DfMA) principles at the pace required.

Over the past five-years or so the offsite industry has changed significantly – mainly down to the numbers of new entrants into the manufacturing space and the consistency of messaging from Government. I am concerned that many of the new players do not really understand the magnitude of the challenge that our offsite manufacturing industry faces in scaling up and making the transition to a key player, and we are yet to see many significant successes at scale.

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PROVIDING A BETTER BUILT ENVIRONMENT Build back better is the Government’s current mantra and with the housing shortfall there has been an emphasis on the residential sector, but offsite technology is adaptable and capable of providing solutions across all vertical markets from housing to infrastructure and everything in between. We have seen significant uptake of offsite technology in education and now healthcare. Retail, leisure, hotels and student accommodation sectors have all been huge consumers of offsite technology and offsite methods are now the norm – not even debated but now assumed. One of my biggest frustrations is the lack of technology migration and knowledge transfer from some of these vertical markets across to housebuilding, so we end up seeing a lot of ‘reinventing’ the wheel instead

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of ‘evolution’. That said, we are seeing significant progression with the uptake of light steel framing technology in the rapidly emerging build to rent sector, to cite just one ‘hot spot’ which is driven by the requirement to develop robust, energy efficient, safe and compliant systems at pace to reduce operating costs across the lifetime of these buildings.

ENTERING THE OFFSITE ARENA Cogent advises many across the construction industry on developing businesses at all levels but we do not underestimate the task in hand. A new initiative or manufacturing investment requires deep pockets and specialist skills. Entering the offsite sector requires time, money and resource to be planned accurately and significant contingencies need to be allowed for – especially around areas of testing, validation and certification.

Making sure that the prototyping and pre-production phases are not shortcircuited is another vital element, as these are the most valuable part of the process. The danger is that you develop a technology that is fantastic in-situ but very difficult to manufacture, or vice versa. The key is to find a blend that suits the business objectives. This is where DfMA comes into play - the focus should be on ‘Assembly’, as there is a strong and indigenous light steel frame manufacturing supply-chain in the UK with skills and expertise to support many of the new offsite developments – especially volumetric modules and pod technology. So, there is no point in bringing processing or roll-rolling inhouse when it is often more efficient to tap into the expertise and resources that is offered by the supply-chain.

KNOWLEDGE SHARING AND COLLABORATION In my opinion those operating in the sector should collaborate for the greater good – the light steel frame sector is better than most as can be witnessed via the rapidly growing Light Steel Frame Association. The real competitor is ‘traditional’ construction not necessarily the next manufacturer down the road. The offsite technology trade associations have a significant

OFFSITE PROGRESSION

role to play in facilitating this, and many of the new entrants in to the offsite manufacturing sector need to be nurtured so as not to unintentionally damage the industry with inferior product developments or system failures. The key is to get the Associations to set the entry level high and to help bring new entrants up to the minimum acceptable level of operational and quality standards.

THE FUTURE IS BRIGHT - THE FUTURE’S OFFSITE As far as the future is concerned, the integration of digital tools is definitely a game-changer, but much of this is often seen to be out of reach for many offsite manufacturers, on the basis that there is a requirement to embed and mature much more fundamental operational processes and procedures before getting too carried away with digital tools.

Digital tools are a fantastic means to an end – they permit external architects and engineers to access and work with offsite manufacturing details, but often the fundamentals are missing

PROCESS-DRIVEN

INNOVATION

or inadequate. These fundamentals include a robust approach to Bill of Materials generation, labour time planning and lead time analysis, stock control systems (ERP) and basic production capacity planning tools that are the spine of any well-run manufacturing or assembly operation.

No matter how forward-looking we are in terms of digital tools – BIM, AR/VR, AI for example – unless we get the basics right it is a futile exercise. The key is to ensure our offsite manufacturing base in the UK is world-class in its adoption of reliable and robust manufacturing operations and repeatable processes, before getting too carried away with the front-end digital tools.

As for the next five-years are concerned – I would forecast that we will see lots of mergers and acquisitions in the offing, supported by an increasing influx of ‘outside cash’ as some of the leading offsite manufacturing players begin to show decent financial returns and the venture capitalists and wellheeled private investors begin to see the medium to long-term potential of the sector. I am certain that we will

COLLABORATION

see greater support and collaboration.

I hope we will see much greater migration of personnel from the automotive and aerospace sectors to the offsite manufacturing industry as bringing with them an abundance of knowledge and skills around world class manufacturing processes and protocols – this will be the real gamechanger.

Whatever happens, I am certain that we face an exciting future and that our industry will continue to flourish.

For more information visit: www.cogent-consulting.co.uk

Intelligent Steel Solutions design manufacture and install their own load bearing Light Gauge Steel Framing system and supply SFS infill and components for the Modular and Construction industry.

To find out more about the new features and benefits that Intelligent Steel can offer or if you have a new build scheme that you’d like to discuss either in person (safe & socially distanced) or via TEAMS/ Zoom, please contact David:

Operating in the following sectors: RESIDENTIAL INCLUDING HOUSING & APARTMENTS | STUDENT ACCOMMODATION | HOTELS | CARE HOMES & RETIREMENT LIVING | EDUCATION | HEALTHCARE | COMMERCIAL

MANUFACTURING MEMBER

M: 07800 585245 | T: 0191 594 7200 E: david.ellison@intelligentsteel.com Intelligent Steel Solutions

www.intelligentsteel.com

CASE STUDY

BIM STRUCTURAL STEEL DETAILING DELIVERED EARLY THANKS TO BIM

ADVANCE STEEL AND BIM COLLABORATION HELPED STEEL FABRICATOR TSI STRUCTURES, DELIVER A NEW MATERNITY UNIT ON TIME. THE SOFTWARE’S EASE OF USE, SPEED OF MODELLING, CONNECTION DESIGN AND INTEGRATED DESIGN CHECKS – COMBINED WITH THE ABILITY TO REUSE THE STRUCTURAL ENGINEER’S REVIT MODEL – HELPED REDUCE TSI STRUCTURES’ ANTICIPATED SCHEDULE TIME

BY APPROXIMATELY 20%.

Kettering General Hospital in Northamptonshire completely replaced its old maternity and with a new £4.5million expansion and renovation.

Steel fabricator TSI Structures provided steel connection design, detailing, fabrication, and erection for the new expansion.

The hospital’s existing maternity operating rooms and facilities had become outdated and were causing inefficiencies in services. “We had an uncompromising schedule for our drawings and steel works,” explains

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Adrian Betts, TSI’s Drawing Office Manager. “Adding to our schedule challenge was the requirement that we provide full connection design to the new Eurocode 3 that is replacing an existing British Standard code.”

The extended project team including TSI, the general contractor Interserve, and BWB Consulting for structural engineering – were all required to use some of the collaborative BIM practices that are now mandated for all UK government public projects, including the sharing of model-based project data amongst the project team.

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THE SOLUTION TSI used Autodesk® Advance Steel software for its steel connection design, detailing, and fabrication on this project and Advance Steel’s built-in steel connection design engine which fully supports the Eurocode 3 to check connections in real time. Furthermore, the Advance Steel model was used to automatically generate CNC data for TSI’s fabrication processes.

“The bi-directional link between Advance Steel and Autodesk® Revit software— used by BWB’s structural engineers—made it easier to reuse their design model and work more efficiently with their engineers using a BIM workflow,” says Adrian Betts. “Due to this link, as well as the accuracy and detail of BWB’s model, we did not have to waste time recreating the steel model in Advance Steel and could immediately start adding our steel connections.”

During the project, TSI uploaded its Advance Steel model, drawings, and reports to the contractor’s common data environment. BIM mandate was used to collect, manage, and disseminate all relevant approved project documents for multidisciplinary teams and ultimately the facility owner. Along with the native Advance Steel model, TSI also exported and uploaded Industry Foundation Classes (IFC) models of its steel design. In addition, the company provided a brief instructional video for the extended project team members who used Revit—and eventually the hospital if they choose to use Revit for their ongoing facility operations—that explained how to get the Advance Steel Plug-in for Revit® from the Autodesk® App Store and how to open TSI’s model in Revit to help synchronise or check it against their own models and drawings.

For more information visit: www.autodesk.com IMAGES 01. TSI Structures used Autodesk® Advance

Steel software for its steel connection

design, detailing, and fabrication on this project.

ADVERTORIAL

SIMPSON STRONG-TIE ALL NEW LIGHT GAUGE STEEL RANGE Simpson Strong-Tie is set to provide the steel frame construction industry with performance tested connectors and fixings with the release of their brand new 2021 Connectors for Light Gauge Steel catalogue.

Created for suppliers, architects, engineers, erectors, and contractors alike, the new catalogue makes it easy to specify project-appropriate connector solutions – a must-have for manufacturers of light gauge steel load-bearing structures or facades.

Alongside the ever popular TJC Jack Truss and Rafter Connector, an on-site adjustable angle bracket, HTT5 Tension Ties and the Quik Drive collated fastening system sit brand new product innovations:

• The LGSSC Splicing Clip connects over–sail LGS studs to the primary structure •

The RCKW Parapet Wall Bracket resists an over-turning moment at the base of exterior knee-walls and parapets

• X1214 screws are capable of drilling through 5mm steel and suitable for 450 grade hardened steel • X1224 screws are capable of drilling through 12.5mm steel and suitable for fixing to hot rolled steel sections

“Our range of connectors can assist on-site installation and ensure projects are completed on time and to your specification," explains Sales Manager Keith Lister. “Our dedicated technical support team are available daily to help you select your connector and the fixing solution.”

Download the catalogue at: www.strongtie.co.uk

Our widest range of Light Gauge Steel products to date, designed to make life simpler for builders, engineers and architects.

Pick up your copy of our brand NEW Connectors and Fasteners for Light Gauge Steel 2021 Catalogue.

Building Safer, Stronger Structures.

Connect with us: 01827 255600 | www.strongtie.co.uk |

@strongtieUK

STEEL CONSTRUCTION INSTITUTE

CONTINUOUS TECHNICAL SUPPORT AND DEVELOPMENT

01

ANDREW WAY, ASSOCIATE DIRECTOR AT SCI EXPLAINS THE IMPORTANCE OF THE SCI’S CONTINUED TECHNICAL SUPPORT TO THE LIGHT STEEL FRAMING SECTOR, AND HOW TECHNICAL DEVELOPMENT OF LIGHT STEEL FRAMING CONTINUES TO THRIVE. GUIDANCE AND DISSEMINATION Since its inception The Steel Construction Institute (SCI) has had an overarching objective to promote the effective use of steel in construction.

This has included fundamental research and technical development of light steel framing systems for over 25 years. My own personal involvement with light steel framing at the SCI goes back a little over 15 years (as during the early years of my career I was more involved with hot rolled steel frames and sheet piling coffer dams).

Over the years the SCI has disseminated their work in multiple technical publications and design guides which have been used by the industry and have been fundamental to the growth of the light steel framing sector and the wider acceptance of this technology. The work of the

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SCI and their publications has given the credibility to this once emerging method of construction. Many of these publications have of course been updated since their original release and other publications are in the pipeline.

CERTIFICATION AND VERIFICATION Despite the significant amount of guidance for light steel framing and cold formed steel design (over 50 publications from SCI, plus national design standards, codes of practice and publications from other organisations) there continues to be a need for more guidance and more information. One of the services the SCI provides to its members is the Advisory Desk, calls are regularly received from practitioners looking for guidance on situations which they cannot find covered in guidance documents. Of course, not all situations and scenarios can be

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included in published guidance, and in these circumstances, SCI are able to offer advice. In many cases it will be necessary to apply engineering first principals to a problem, or perhaps consider the use of structural testing, depending on the topic.

However, where design methods are described in guidance documents or national standards, it is imperative that they are applied correctly. The process of third-party certification and verification enables any errors or misunderstandings in application to be identified and corrected. The SCI currently operates three types of certification; • SCI Assessed, • SCI Product Certification, • SCI/NHBC Stage 1 System

STEEL CONSTRUCTION INSTITUTE

CERTIFICATION With all three schemes it is extremely rare that the initial technical submission which is received by SCI is the same as the final submission which is accepted for certification. There are various reasons why changes are required to the technical submission and these cover a range of severities in terms of implications for the final design. In all cases where the certification has been completed, the companies involved have appreciated the benefits that come from the review process and in some cases the resulting improvements to their design methods. The use of third-party verification is particularly important as technical development and innovation with light steel framing systems continues to thrive.

Readers may be aware of a scheme recently launched by NHBC called ‘NHBC Accepts’. This is a separate scheme to SCI/NHBC Stage 1 System Certification, however, for light steel frame systems one of the requirements to achieving NHBC Accepts is having a valid Stage 1 certificate from the SCI.

the scheme. Companies with a valid certificate will also be able to use the new logo individually on their marketing materials and websites.

02 NEW LOGO The SCI/NHBC Stage 1 System Certification scheme is specifically for light steel framing systems in accordance with Chapter 6.10 of the NHBC Standards. However, until recently there has not been a specific logo for companies to use after they have achieved the certificate. This situation was addressed with the creation of a new logo which will help to differentiate between SCI’s other assessment and certification schemes.

The new style certificates are issued as new certifications are achieved and as old-style certificates are successfully renewed. Any companies with an existing valid Stage 1 Certificate can contact SCI at assessment@steel-sci.com to request the new SCI/NHBC Stage 1 System Certification logo.

For more information visit: www.steel-sci.com IMAGES 01. A selection of SCI publication covers old

and new 02. New logo for SCI/NHBC Stage 1 System Certification

Since July 2020 our new logo has been used on the full technical certificates and also on the one-page display certificates which are issued with

SCI Support for the Light Steel industry With over 30 years of expertise in the steel industry SCI are able to support the light steel industry in a number of ways.

Assessment and Certification Enhance your market share with added assurance for specifiers that products and processes meet current standards and regulations.

Light Steel Forum An SCI membership group whose objective is the technical development of light steel construction systems.

T: +44 (0)1344 636525 assessment@steel-sci.com | www.steel-sci.com

Industry Design Standards SCI supports the industry with many technical resources and are involved at Eurocode committee level to improve standards.

FOCUS ON FRAMING

DEDICATED STEEL FRAMING SEMINAR RETURNS AS A MINI-SERIES FOR 2021 FOCUS ON FRAMING – THE INFORMATIVE AND INTERACTIVE SEMINAR WITH SUPPORTING EXHIBITION HOSTED BY THE LIGHT STEEL FRAME ASSOCIATION (LSFA) - WILL RETURN AS A MINI-SERIES THROUGHOUT 2021 TO BRING TOGETHER LIGHT STEEL FRAME MANUFACTURERS AND INDUSTRY PROFESSIONALS.

Following the Building Regulations that came into force at the end of 2018, restricting the use of combustible materials in external walls of residential buildings above 18m, the spotlight has turned to steel framing. Focus on Framing seeks to provide construction professionals with insight into the latest compliant light steel frame systems and showcase best practice through informative case studies, presented by market leaders and their clients.

The Focus on Framing seminars seek to highlight light steel framing solutions to overcome the challenges presented by new protocols; each seminar will feature presentations on globally recognised projects that demonstrate the newest innovations and developments in this ever-changing sector.

These events have been created for specifiers, engineers, architects, contractors, housebuilders, developers and manufacturers who are looking to explore the latest technological advancements and solutions to overcome the challenges presented by new building regulations.

David Ellison, Director of Business Development, Intelligent Steel commented: “This is a very close-knit industry and we all feed off each other in certain ways. I’m always happy to praise the competition that’s out there because complacency won’t allow us to improve and innovate. We all need to do a great job to maintain our image, raise awareness and promote our success stories for the betterment of all. Events such as Focus on Framing gives us the opportunity to celebrate our success, promote the systems available and network with like-minded professionals.”

Mike Fairey, Director, Fusion Building Systems added: “Attending industry events has taken on a new guise in 2020 with delegates finding themselves forced to engage remotely. However, whether in person or in a virtual environment, industry events provide the opportunity for all to learn, network and be inspired. I think even more so now as we are siloed into our own bubbles, we need to connect with others to maintain the energy which is necessary to drive our market sector forward.”

Event sponsor and host, the Light Steel Frame Association (LSFA), are on a mission to emphasise the benefits of steel as a rigid and robust non-combustible offsite solution. The LSFA provide a unified voice within the industry to promote the levels of sophistication, innovation and technical expertise within the sector.

To register your interest in receiving more information on the 2021 Focus on Framing Seminar Programme, please contact: jessica.holland@radar-communications.co.uk

To stay up to date with LSF industry news, please visit: www.lsf-association.co.uk 44

LIGHTSTEELFRAMINGMAGAZINE.CO.UK

FOCUS ON

FRAMING

SEMINAR

Displaying ground breaking innovation through light steel framing solutions.

The use of Light Steel Frame is fundamental as a construction material within a wide range of building types and applications in the offsite sector.

FOCUS ON FRAMING provides the opportunity to hear insightful case studies from those who are designing and developing the industry’s ground-breaking projects. The seminars will be complimented by an exhibition of leading businesses across the sector, and provide networking prospects with those who are shaping the future of the Light Steel Frame industry.

Bringing together Light Steel Frame professionals through a mini-series of seminars throughout 2021 If you are involved in ground-breaking projects or developing pioneering strategies and would like to share your knowledge and expertise with an engaging audience, please email your name, company and proposed presentation title with description to:

jessica.holland@radar-communications.co.uk

FOCUS ON FRAMING is delivered in partnership with the LIGHT STEEL FRAME ASSOCIATION, which has been established to support the overall objectives and growth of the light steel framing sector.

For more event information visit www.focusonframing.co.uk

OUR 2021 FLOORPLAN IS NOW AVAILABLE For more information or to book your stand, contact julie.williams@radar-communications.co.uk or call 01743 290042

JOIN OUR LEADERS IN LIGHT STEEL FRAMING TECHNOLOGY AT OFFSITE EXPO

#OffsiteExpo

#ExploreOffsite

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WWW.OFFSITE-EXPO.CO.UK

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