Offsite Magazine - Issue 31 (March/April 2022)

P24

PRODUCT PLATFORM RULEBOOK

The Construction Innovation Hub gets ready to unveil its recent workshop and development findings

P40

REDEFINING MMC

The future of UK housing design lies not only in ‘modern’ but in ‘many methods of construction’

P48

PROJECT SPEED & OFFSITE

The Association for Consultancy and Engineering on maximising offsite opportunities faster

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PLATFORM FOR PRODUCTIVITY

Welcome to the latest Offsite Magazine. This issue has a wideranging set of features from the first quarter of 2022 – a one that has started with the pandemic receding and supply chains stabilising to be replaced with the dreadful conflict raging in Ukraine that will undoubtedly bring more economic pressures.

At the end of last year, the Construction Innovation Hub’s Platform Programme published ‘The Road to the Rulebook’, summarising feedback received via extensive stakeholder consultation, to introduce the concept of platformbased approaches in construction. Inside, Trudi Sully, Impact Director at the Hub, outlines the ‘why, what and how’ of product platforms and what to expect from the soon to be published (as we went to print) first draft of the Product Platform Rulebook.

Our lead Q&A feature this issue comes from a familiar face in the offsite sector. Professor Robert Hairstans has a deep understanding of timber and the offsite sector, and as Director of the new Centre for Advanced Timber Technology – opening in July – at the New Model Institute for Technology and Engineering, he took some time to describe how offsite manufacture fits into sustainable construction and as an integral part of Industry 4.0, digitisation

and the further development of skills needed for Industry 5.0 –where the collaboration of ‘human skills and digitisation’ will see more concentration on tasks in production and mass customisation.

A third highlight this issue comes from the Association for Consultancy and Engineering. Its recent report ‘Project Speed and off-site manufacturing’ outlines the decisive action still needed by Government and industry to make offsite manufacture an everyday reality. Head of Policy, Guto Davies, picks out some of the report’s key conclusions and what future industry leaders should be aiming for including a ‘ten-year overarching offsite strategy’ to deliver a ‘clear vision, ambitious objectives and goals, well-considered critical success factors, a time-bound plan with discrete milestones and metrics to measure progress.’

Plenty more inside and finally – as one of the judges for the Offsite Awards 2022 – I would be slacking if I didn’t remind you that the 27 May closing date for entry submissions is fast approaching. Don’t miss it!

As ever, many thanks to all our contributors, advertisers and supporters.

Gary Ramsay Consultant Editor

Email: gary.ramsay@offsitemagazine.co.uk

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COVER STORIES

P06 | PRECAST SOLUTIONS PERFECT FOR SUDS

Carlow Concrete designs and manufactures its modular precast concrete systems at a state-of-the-art facility in Ireland. Recognised and used by water companies and local councils, its stormwater attenuation tanks satisfy mandatory SUDS requirements and are fully S104 adoption compliant.

P40 | REDEFINING MMC

David Robins, Head of Central Technical Services at Places for People, explores just what MMC processes are at hand to housebuilders looking to create new homes at scale – and why he believes a construction mix is the key to the future.

NEWS

08 | Industry News

News and developments from across the UK offsite industry and wider construction arena including: AIMCH’s new housing pattern book to transform affordable homes delivery, Stewart Milne Timber Systems rebrands, HE Simm Group invests £1million in MEP facility and FTSE 250 company Bellway delivers its first modular homes.

P24 | DESIGNING IN CHANGE

Last year, the Construction Innovation Hub’s Platform Programme published the findings from a series of workshops and development activity. Trudi Sully, Impact Director at the Hub outlines what to expect, with the first draft of the Product Platform Rulebook soon to be published.

P48 | REALISING OFFSITE’S HUGE POTENTIAL

As offsite manufacture continues to make advances in construction thinking, Government ambitions regarding offsite are not being met, argues Guto Davies, Head of Policy at the Association for Consultancy and Engineering.

FEATURES

28 | Adapting and Developing Industry 4.0

Professor Robert Hairstans, Director of the Centre for Advanced Timber Technology (CATT) at the New Model Institute for Technology and Engineering (NMITIE) has a deep knowledge and understanding of timber and the offsite sector. How do these fit into the wider requirements of sustainable construction?

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CONTENTS

34 | Can Volumetric Deliver a Net Zero Future?

Is the road to a net zero future a well mapped out route or is there uncertainty along the way? Richard Hipkiss, Development Director of the MPBA, makes the case for volumetric buildings shaping a more sustainable future.

38 | Shifting Perceptions on MMC

Will 2022 be the year we see a real shift toward the use of MMC in residential developments? Tim Reid, Customer Relationship Director at NHBC, sees a range of opportunities ahead.

42 | Modernising the UK’s Approach to Housing Delivery

Darren Richards, Managing Director at Cogent Consulting, points out how housebuilding can play a vital role in the UK’s post-pandemic recovery.

44 | Frameworks in Action

Boho 8, the most recent phase of Middlesbrough’s Boho Zone, has seen modular methods transform the area.

50 | The Adaptable Interim Housing Solution

VOLUMETRIC™ has been working with many sectors to address accommodation needs and its MODULHAUS™ can now be configured to meet various keyworker accommodation requirements.

60 | Building New Homes and Meeting Climate Targets

AIMCH recently concluded that using sustainably sourced panelised timber systems could transform housing delivery. Stewart Dalgarno, AIMCH Project Director explains more.

62 | Bringing Accuracy to Offsite

Offsite construction provides many benefits and at its core is the need for accuracy. Nick Milestone, Operations Director at Sigmat, explains why BIM is a perfect partner for factory-based manufacture.

70 | Decarbonising Project Design

As a core material to construction, concrete is under pressure to provide details on its sustainability credentials and accelerate the drive to net zero carbon.

72 | Promoting Tried and Trusted

Lee Jones, Head of Manufacturing Solutions at NBS, outlines why marketing in the era of the ‘Code for Construction Product Information’ may be unlike any other era for construction information.

Banner ads , also known as display ads, are an extremely cost-effective way to reach a dedicated audience and attractively display your products and services online, increase your brand recognition and assist with your website SEO. With over 5,000 visitors every month, the Offsite Hub provides the ideal opportunity for you to reach your target audience.

Our offsite portfolio includes an abundance of profile-raising opportunities and this is just one way you can get involved!

For more information contact a member of our team on 01743 290001

PRECAST SOLUTIONS PERFECT FOR SUDS

Carlow Concrete designs and manufactures its modular precast concrete systems at a state-of-the-art facility in Ireland for direct supply and installation by market affiliates and trade partners.

Carlow Concrete was established in 2016 by Enda Byrne and MJ Lomax both of whom together have over 40 years relevant experience in senior management positions in the construction products and concrete industry.

The company was established primarily to design, build, and install modular offsite building solutions to both the Irish and UK construction sectors. The initial offering was stormwater attenuation tanks and flood alleviation tanks for sale to water authorities and residential programmes in UK and Ireland and more recently into northern Europe. Irish and UK authorities stipulate that all development sites and designated catchment areas must detain excess stormwater on-site for predetermined durations to reduce flood risk.

1The Carlow Concrete modular tank enables clients to satisfy these mandatory sustainable urban drainage (SUDS) obligations. The Carlow attenuation tank is the most economical means of meeting these standards. Design of highly functional and economic solutions reflect our full understanding of regulatory standards, best installation practice, buyer needs and economic modelling.

The Carlow Concrete Approach

In 2016 Carlow Concrete entered the market by targeting water companies and affiliates with a highly specialised and technical offering. Trust was gained through successful bidding and completion of small and complex projects. Seven years on: Carlow has been appointed as supply chain partner to several water companies, guaranteeing Asset Management

Programme 7 (AMP7) involvement on major capital flooding schemes over the five-year period. The outlook for the water sector is very stable with annual upgrade and renewal budgets constant.

Unique Selling Point

The competitive position is underpinned by the deep technical knowledge and experience of the founding Directors MJ Lomax – who has twenty years in the precast concrete industry – and Enda Byrne, a qualified structural engineer who spent 18 years in construction and consultancy.

The extensive market knowledge and trade connections are reflected in the innovative modular design and service processes which are supported by a very lean and efficient production model, which together define a sustainable competitive position. Factory production of modular units is easier, more efficient and cost effective. It facilitates higher levels of quality control than that of traditional on-site construction methods. The production of stock items ensures constant availability. Carlow Concrete is also highly committed to minimising the impact of its activities on both the local and global environments.

In line with this commitment, we implement carbon accounting and management protocols in accordance with ISO 14064: ‘Greenhouse Gases’ specification, with guidance at the organisational level for quantification and reporting of greenhouse gas emissions and removals. Project specific carbon budgets are produced upon customer’s request. Carbon accounting now being a major component of bid analysis by our customers.

Why Carlow Stormwater Attenuation Tanks?

To combat flooding, both Irish and UK building authorities stipulate a restriction on the rate of storm water flow from the developed site to that of the original ‘greenfield’ condition. In many cases the most economical means of achieving this is to place a flow control device on the site outlet and to detain excess run off in subsurface stormwater attenuation tanks.

Recognised by water companies and local councils, our stormwater attenuation tanks satisfy mandatory SUDS requirements and are fully S104 adoption compliant. Carlow Concrete prides itself on continuous design innovation and improvement, and in terms of stormwater attenuation, the Carlow Tank offers clients the most efficiently and economically designed solution in its class. Our stormwater attenuation tanks are the most robust on the market and can be located in highly trafficked areas such as roads and carparks.

At Carlow Concrete a key ingredient of quality production are our technicians and in-house concrete testing lab. To back this up in delivering the best possible stormwater attenuation solution, an ID tag provides each element of an installation with its own unique reference number, so it is fully traceable from production to final location.

Innovation

The business is highly design and innovation lead. To date the priority has been on developing a core range of modular solutions to meet the specific needs and standards of the water companies and housing developers. Within the factory, process effectiveness and efficiency are being constantly monitored and improved through better methodologies and mould designs. Over the last 24 months the emphasis has moved to new product design and increased productisation of solutions for residential applications where the potential scope to scale business is significant and sustainable.

Production & Future Expansion

The fully integrated operation in Carlow is accessible to Dublin and Rosslare ports. Production buildings of over 750sq m which is ideal for

COVER STORY CARLOW CONCRETE

large scale production and graduated expansion. Core functions include design, estimating, NPD, technical lab and QA, mould-design, production and logistics. All production is made to relevant ISO standards and industry best practice. At design stage each project undergoes rigorous structural design using cutting edge analysis software and the option of 3D BIM Modelling at both approval and construction stages. The production cycle from mould set-up to ex-factory delivery averages 10 days and current plant capacity is approximately 60,000 tonnes of precast concrete products per annum.

Expanding into larger markets, other than the UK is a logical step and is part of Carlow Concrete’s long-term strategy. Our research has confirmed that similar to the UK and Irish markets,

significant amounts of technical expertise, accreditations and quality control are essential for new entrants to the northern European markets. The replacement of the British Standards by the new Eurocodes, in the Euro Zone, has been of huge importance to Carlow Concrete. Carlow Concrete has been designing to the new codes since their introduction and are now experts in the new standards of design. All 27 EU-member states now require the design of all building structures to be in strict compliance to the Eurocodes.

For more information visit: www.carlowconcrete.com

Images:

01-03. Precast concrete is ideal for producing modular stormwater attenuation tanks

Elliott Completes New Best-Value Primary School in 32 Weeks

Development of a new school in Redhill, Surrey, has been completed in just 32 weeks thanks to the speed and versatility of the Elliott permanent modular building system.

Built to provide additional school places because of new residential developments and increasing birth rates in the area, the BREEAM Very Good-rated Hatchlands Primary School has been developed as part of Department for Education’s (DfE) Modular-A Primary School framework. Elliott was awarded the project because it demonstrated excellent value for money and was able to provide a full turnkey solution. The modular manufacturer worked closely with award-winning designers DLA Architecture to create a contemporary high-performance building sympathetic to its environment.

Located adjacent to a Conservation Area on what was once a challenging urban brownfield site, offsite construction of the school used the Elliott Ibex permanent modular building system. Modules were delivered with a high Pre-Manufactured Value and ready for final finishing on site. This reduced the construction schedule by around 50% compared to a traditional on-site build. Elliott routinely achieves MPV’s of over 80% using its offsite construction solutions.

The Ibex system is fully building regulations compliant with passive ventilation and has a minimum 60-year design life. Hatchlands Primary School features a contemporary style aesthetic achieved using brick, cedar cladding, purple panelling to complement the school’s branding, render and significant glazed elements to create light-filled teaching spaces.

A large span sports hall uses the Elliott Hybrid system, providing the school with a valuable space that is now used for assemblies, sports and performances. The system allows incorporation of large open atriums and increased ceiling heights and can be fully integrated with the modules to provide greater design scope.

The school was also built to high sustainability standards and achieves a BREEAM Very Good rating. This means it is within the top 25% of buildings in terms of sustainability, aligning with the goals of Reigate and Banstead Borough Council. A suspended concrete floor helps to minimise transmittance of noise, meeting minimum standards set out in The Building Bulletin 93 (BB 93) ‘Acoustic Design of Schools: A Design Guide’. The completed school is indistinguishable to a traditional on-site build yet delivers all the benefits of offsite construction; a shorter 32 week build schedule, less site traffic,

more consistent build quality, a reduction of on-site waste and future reconfigurability and recyclability.

Graham Stevenson, Construction Manager at Elliott, said: “Completing Hatchlands Primary School in just 32 weeks is testament to the dedication of all project partners and benefits of our offsite systems. The new school is an important and exciting development for the community and we hope that it will inspire some of the pupils to take up a career in construction.”

Moira Anderson, Headteacher at Hatchlands Primary School, commented: “What a fabulous new school we now have. The children were really excited about moving into their new classrooms and it is certainly very different to the temporary teaching areas we have been using. We were all really impressed with the professionalism and considerate approach of the Elliott team.”

Elliott and its affiliated UK companies have a new face, new name and have united under the common brand name of Algeco. For more on this see p26.

Source: www.elliott uk.com

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Sajid Javid Opens Latest MTX Project

The Secretary of State for Health and Social Care, the Rt Hon Sajid Javid MP, officially opened the latest project to be completed by offsite building specialist, MTX, at Leighton Hospital in Crewe.

The 4200sq m two-storey development provided the Mid Cheshire Trust with an A&E department extension that offers a larger, better, and safer environment for patients and staff, whilst helping to combat the extended waiting lists that the NHS is currently facing due to the pandemic.

The development is comprised of ground floor treatment rooms including, rapid assessment bays, isolation and resus bays, a bereavement suite, x-ray facilities, as well as a dedicated paediatric unit and mental health assessment rooms. On the first-floor level, a large number of offices and staff areas have been created. The extension was delivered following the Trust successfully securing Government funding last year.

Steven Hartley, Project Director from MTX heading up the Leighton Hospital works, said: “Efficiency has never been more important in the healthcare industry, especially during these unprecedented times. The project we delivered for Leighton Hospital will allow the Trust to provide greater clinical effectiveness for both patients and staff.

Rollalong Appoints New Manufacturing Director

Modular manufacturer Rollalong has appointed a new Manufacturing Director, whose varied career has spanned several sectors, from confectionery to marine machining. Michelle Davies joins the senior team at the largest permanent offsite manufacturer in the south of England, bringing with her years of expertise in various manufacturing management roles.

“The new department sees the relocation of the ambulatory care services into the new increased capacity facility, in essence, creating an urgent care village which not only reduces patient assessment times, but supports a more cohesive working and overall improved patient experience.’ We’re incredibly proud that the Secretary of State was able to make the visit to open the newly completed project at Leighton Hospital.”

James Sumner, Chief Executive of the Mid Cheshire Trust, added: “We were delighted to welcome the Secretary of State to Leighton, at a time when we are investing in enhanced hospital services for our local community. The purpose-built A&E ensures a bigger, better, and safer environment for both patients

“I joined Rollalong because I saw an opportunity to challenge my skill sets in business management and work with a team that is dedicated to their industry,” said Michelle. “Rollalong is a successful company employing skilled local people. The team has been great in welcoming me and helping me understand all things modular.”

Michelle has several aims and objectives to achieve in her new role, such as improving production processes and flows to achieve target hours, costs and client requirements, maintaining strong communications between production and the rest of the business, and reviewing opportunities to automate, all while continuing to manufacture a high-quality product.

However, Michelle has not always worked in the modular or construction industries; in fact, her first role was in confectionery. “My career began working up from the shop floor in the confectionery industry all the way up to Production Manager,” said Michelle. “From there I became a Production Manager building caravans for the leisure industry and then transferred to General Manager in metal fabrication and machining for the marine and architectural sectors. I am well respected within the marine industry, having worked closely with production builders and class surveyors.

and staff. A&E attendance has increased across the country in recent years, so this provides an excellent opportunity to meet the needs of our growing population of 300,000.”

Dr David Matthews, Clinical Director of Emergency Care, concluded: “The NHS has been tested to the maximum by a combination of higher patient attendances, the Coronavirus pandemic and the annual winter pressures. This facility is really exciting for the Trust – it has been carefully designed to allow for the clear separation of children and adults in a modern, welcoming environment that will greatly improve the patient experience.”

Source: www.mtxcontracts.co.uk

“I’ve learned valuable transferable skills throughout my career such as management of people and process control, both of which I’m excited to bring to the table at Rollalong. Engineering is also the base skill for this product which I have experience in, and over the next couple of years I’ll be expanding my knowledge on modular builds. I’m thrilled to be working at Rollalong, it’s been a steep learning curve since my appointment, and I have loved every second. There’s always an exciting new project to work on while using R&D to improve our work along the way.”

Rollalong’s Managing Director Steve Chivers commented: “We are delighted to welcome Michelle who brings a wealth of knowledge and experience to the team. We have a strong pipeline of work, and we are committed to delivering a quality product for all of our valued clients. Michelle has joined us to ensure that Rollalong’s manufacturing capabilities meet the strategic needs of the business over the next few years, delivering efficiency improvements and digital solutions to create a solid foundation for the manufacturing team to grow and sustain itself in alignment with the positive growth curve of the company.”

Source: www.rollalong.co.uk

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Seismic Unveil New Platform-based Approach

The Seismic demonstrator is the culmination of a four-year project developed by a consortium comprising consultancy blacc, offsite manufacturers Elliott Group and the McAvoy, Tata Steel, the Manufacturing Technology Centre (MTC), the National Composite Centre (NCC) and Specific (part of Swansea University).

Designed in line with the government’s Construction 2025 targets, it exceeds them in every way, delivering a building that is 75% faster to complete, 70% lower in carbon impact and 47% better value than traditional construction. One of the unique aspects of the project is the combination of three manufacturers working independently on the same building. The demonstrator shows this to good effect incorporating systems from McAvoy, Elliott Group and Tata Steel.

Richard Crosby, Director at blacc, said: “Seismic was developed to help drive a shift towards modern methods of construction (MMC) in the industry. What the consortium has achieved demonstrates the value of a standardised, platform-based approach to construction. It is faster at every stage, from design through to manufacturing, assembly and fitout, and offers better quality and value, alongside a dramatically lower carbon impact. Seismic sets the template for a platform-based approach to construction and proves that it can be done now. This offers a huge opportunity for unlocking development, providing a solution for a range of sectors, including education, healthcare, workplace, leisure and residential.”

Seismic has been worked on in two stages. Phase one was developed in response to work with the Department for Education (DfE) to improve the delivery of schools. It focused on the design of a standardised, lightweight steel frame and connector and was completed in 2020. Because of its success, a second stage was commissioned. The objective

was to design and construct core components that would work with the frame system, including wall, floor, ceiling and roof cassettes, offering an ‘all-in-one’ solution for clients.

Sam Stacey, Challenge Director for Transforming Construction, said: “Most modular construction relies on bespoke systems created by individual manufacturers. A lack of standardisation means that different systems are incompatible, which adds risk for clients, especially once they take on responsibility for the building’s operation and maintenance. What Seismic shows is that if everyone works to one system it is possible to deliver buildings much more effectively, whether compared with existing modular techniques or traditional construction.”

The National Composites Centre (NCC) was appointed to analyse and recommend the best materials to be used for the platform. It also developed a window shroud which was used within the demonstrator building. This supported a wider package of work led by Specific, part of Swansea University, to assess the carbon impacts of Seismic. This looked at the whole process including design, materials, manufacturing, component performance and logistics.

The analysis showed that a standard Seismic module comprises 581.3 kgCO2e per sq m, well below Construction 2025’s target of 1,300 kgCO2e per sq m. And, because Seismic can be reused, either by relocating modules to other sites or by refurbishing individual components and cassettes, it adds a 234 kgCO2e per sq m clawback. This brings Seismic well beyond even the lowest stretch targets being discussed in construction today.

People can visit the demonstrator building at BRE Watford until the end of the year. To find out more visit: www.seismicgroup.co

Precast Foundation System Welcomed to NHBC Accepts

NHBC has announced that Roger Bullivant’s RBeam precast concrete foundation system has been officially welcomed to NHBC Accepts. NHBC Accepts is an all-inclusive, end-to-end service that helps to build confidence in innovative construction and enables innovative products to be fast-tracked for NHBC warranty.

As part of the new service, detailed and robust technical reviews of design, manufacture, and construction result in the provision of a certified usage license for a bespoke NHBC Accepts logo and website listing. NHBC’s Innovation Manager, Richard Lankshear, said: “Following a thorough approval process we are delighted to welcome Roger Bullivant Limited to NHBC Accepts.

“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. NHBC Accepts will play a critical role in ensuring developers, manufacturers, lenders, and consumers have faith and confidence in the quality of new homes built with innovative forms of construction.”

The RBeam is a factory-produced reinforced precast concrete foundation system for low-rise developments. The system is used with a range of piled foundation techniques catering to many different soil types and ground conditions including clay heave situations.

Richard Taylor, Bullivant’s Foundation Systems Director, added: “This approval brings customer confidence and improved productivity on site. We also recognise it as an important achievement in the progression of offsite manufacture in the residential market.”

Bullivant’s Foundation Systems Technical Manager Nigel Rake also said: “Roger Bullivant Limited has been designing, manufacturing, and installing precast foundations for many years. The RBeam system is a category 3 pre-manufactured component under the government’s MMC definition framework and we are very pleased that this has been given a seal of approval for NHBC Accepts. This will provide further assurance in our RBeam system to all our customers and the wider industry.”

Source: www.roger-bullivant.co.uk

UK INDUSTRY NEWS

Basildon Rough Sleepers Get Modular Home

A former adult learning facility will be converted into 10 homes for rough sleepers, with a further six selfcontained SoloHaus offsite homes installed on-site. The Hill Group has gifted the modular homes, and this generous donation, together with the conversion, will result in 60% of Basildon’s homeless being able to live in safe, secure homes and no longer living on the streets.

Planning permission was granted by Basildon Council’s Planning Committee for the former ITEC site in Burnt Mills Road, Basildon. The new development will act as follow-on accommodation specifically for Basildon residents who have found themselves experiencing periods of homelessness. Residents will live in the homes for a maximum of three years, and some will stay for a minimum of six months on an assured shorthold tenancy.

The scheme, which will have office space for support workers, council staff and supporting agencies, has been funded through the Rough Sleeping Accommodation Program (RSAP) from the DLUHC (Department for Levelling Up, Housing & Communities).

The six modular units, known as SoloHaus, have been gifted by The Hill Group as part of their commitment to providing 200 homes over the next five years. They will provide safe, comfortable, sustainable homes for single people experiencing periods of homelessness. The 10 one-bedroom homes inside the building will be managed by the housing association, Peabody South East, in partnership with Basildon Council.

Andy Hill, Chief Executive, The Hill Group, said: “We are delighted to be working with Basildon Council on this scheme which once complete will change peoples’ lives for the better. It is excellent news that

planning has now been approved, and we are looking forward to working with all of the teams to deliver SoloHaus in Essex.”

Chairman of the Housing and Estate Renewal Committee Councillor Andrew Schrader said: “The scheme aims to provide our residents affected by homelessness with a home. Receiving support, vocational training and the skills required to be able to move on and sustain their own tenancy, they will get the opportunity to turn their lives around.”

Source: www.solohaus.co.uk

Donaldson Timber Systems Rebrands from SMTS

The UK’s leading timber frame manufacturer has a new identity. Following its acquisition in 2021, Donaldson Timber Systems (DTS) is the new brand of the business formerly known as Stewart Milne Timber Systems (SMTS).

Established in 1975 as the timber frame arm of the Stewart Milne Group, Donaldson Timber Systems is a pioneer in timber frame technology and manufacturing, operating throughout the UK from three manufacturing plants in Aberdeen, Witney and Falkirk. Since its acquisition in December 2021, all staff and operations have moved over to the Donaldson Group, with Managing Director, Rod Allan and the former SMTS Board of Directors continuing to drive the business.

Alex Goodfellow, formerly Stewart Milne Group Managing Director – Strategic Development, has a new role in the Donaldson Group, as CEO of Donaldson Off-site. Comprising Donaldson Timber Engineering, Donaldson Timber Systems, and Rowan Manufacturing, this new division services the UK housebuilding and construction markets with an unparalleled breadth and depth of products and services.

Donaldson Timber Systems prides itself on being highly sustainable, innovative and efficient. With unrivalled experience and knowledge in timber, DTS has an established history of bringing new commercial and operational innovations to the market. One example is the Sigma II closed panel system offering nearpassivhaus standards of insulation and sustainability. The system is being widely used with housing developers, particularly with those interested in whole life costs and fabric performance, contributing positively to fuel poverty challenges.

The Donaldson Group has over 160 years of expertise in timber importing and distribution, as well as decades of experience in timber engineering and merchanting.

The acquisition strategically and operationally complements the Donaldson Group portfolio and marks the Group’s entry into the timber frame market.

Rod Allan, Managing Director, Donaldson Timber Systems said: “The rebrand to Donaldson Timber Systems is a major milestone in our company history. While the business is moving forward with the same people and operations as before, incorporating the Donaldson name highlights the step-change in our approach. We’re very proud to have joined this longstanding family business, with both timber and people at its heart. The quality of our products and service remains unchanged, but we have many exciting plans and we’re confident that this new venture will prove of great benefit for our customers.”

Andrew Donaldson, CEO of the Donaldson Group added: “It’s been a fantastic few months integrating the new members of the team into the Donaldson Group, and the response from all involved has been hugely positive. This change of name fully aligns the business with the Group and has included a full rebrand including new logo, new branding and new website.

“Now the rebrand exercise is well underway, we’re looking forward to seeing Donaldson Timber Systems develop and grow, building on the excellent foundations that were created in its almost 50 years of operation.”

Currently led by the sixth generation of Donaldson, the Donaldson Group comprises 11 specialist timber and building product businesses, operating throughout the UK from 45 locations employing over 1,500 people.

Pictured: Rod Allan (Managing Director) and Mike Perry (Business Development Director), Donaldson Timber Systems.

Source: www.donaldsontimbersystems.com

Dudleys Delivers Sweet Project

Structural and Civil engineering consultancy, Dudleys has completed works on a major new £34million, light gauge steel frame (LGSF) residential development on Sweet Street in Leeds city centre for its client Oakapple Group.

Pin Yard is a 12-storey build to rent (BTR) scheme of 216 units comprising a mix of studios, one, two, and three-bedroom apartments. The building incorporates a resident’s gym, lounge, co-working spaces, a basement car park and private gardens. It is located on a former warehouse site, adjacent to the Headquarters of Jet 2 in the burgeoning South Bank area of Leeds. Oakapple Group speculatively purchased the site, gained planning consent in 2019, and secured forward funding from Grainger plc, the UK’s largest listed private landlord. The scheme is now handed over to Grainger to operate rentals within its BTR portfolio.

Paul Brownlow, Director at Dudleys said: “We are delighted to complete this significant scheme on behalf of Oakapple Group. As a local consultancy, we are very familiar with the regional landscape and built environment to be able to provide strategic and practical guidance throughout the build programme. The project was not without its challenges due to the tight site constrained by two main roads as well as delays caused by the pandemic. We have worked closely with the delivery team to complete a scheme of exacting standards, using advanced techniques, that we are very proud of.”

Phil Taylor, Chairman of Oakapple Group, added: “It’s certainly not been easy for the team, but despite everything we have all had to face over the last 12 months we continue to work together as a team. We are delighted the project completed successfully in January 2022 and we will definitely look to negotiate further projects with Dudleys.”

Source: www.dudleys.co.uk

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Offsite Alliance

James Latham Officially Launches Carbon Calculator

James Latham Ltd (Lathams), one of the UK’s leading distributors of timber, panels and decorative surfaces, officially launched its powerful new specification tool, the Carbon Calculator at Futurebuild 2022.

Developed in partnership with the University of Bangor the Lathams Carbon Calculator has been designed to help architects and designers better understand the sustainability of the materials they specify. Trialled amongst Lathams’ customers over the past three months, it is already assisting them in selecting the most suitable, sustainable option to meet their respective project requirements. It is also giving specifiers essential assurance that the information they receive relating to a product’s carbon credentials is complete and accurate, from sourcing the raw materials to selection and delivery.

The Carbon Calculator is a back-end tool, designed to achieve transparency and give specifiers confidence when selecting for sustainability. Built using official, publicly available data and manufacturer product information, the Carbon Calculator collates and aggregates the environmental impact of a chosen material, according to three criteria: Carbon Footprint, Embodied Carbon and Data Confidence.

Once evaluated, the product receives a confidence rating from 1-4 (one being the best). The lower the score, the higher the availability and quality of data points reviewed (e.g. published EPDs). The final rating, including carbon data, is then added to quotations,

TopHat Appoints Former FTSE 100 HR Director to Spearhead Growth

TopHat, the Goldman Sachs-backed modular housebuilder, has hired Lucy Weaver, formerly of FTSE100 firm Halma Plc and Unipart Rail (a division of the Unipart Group), as Group HR Director.

invoices, delivery notes, and other key documentation, delivering a tangible, codified proof point. This ensures a robust audit trail for the product, providing valuable information for future carbon reporting and responding to sustainability briefs.

It is important to caveat, even the lowest-rated materials still meet stringent supply requirements, such as mandatory sourcing from sustainably managed forests. Essentially, the Carbon Calculator’s rating is intended to highlight the quality and range of available product information, certification and documentation, informing the specifier if data is based on an estimate or actual performance.

Commenting on the launch of the Carbon Calculator, Ewa Bazydlo, Environmental Manager at Lathams,

Prior to her role at Halma Plc, Weaver worked at Unipart Rail. She was responsible for managing 900 employees across 14 sites across the UK. Weaver has 18 years of experience in manufacturing and logistics, meaning she is well placed to help TopHat reach its growth ambitions.

Weaver will lead the HR agenda for TopHat with a strong focus on recruiting and growing talent and capability as the company looks to increase its current capacity to deliver up to 3,500 factory-built houses and apartments a year by 2025. As part of the recruitment drive, Weaver is set to focus heavily on ensuring that the company hires people from demographics that are currently underrepresented in the construction industry.

Lucy Weaver, Group HR Director at TopHat, said: “It brings me great pleasure to have joined TopHat during such an exciting period for the business.

I’ve been incredibly impressed with what TopHat has achieved in such a short amount of time. The company is continuing to deliver high-quality, highly efficient homes across the country and I look forward to supporting the growth of TopHat over the coming years.”

said: “We feel that this is the latest milestone in an exciting journey towards low-carbon specification across the entire building, construction and design community. By providing a methodology through which the value of sustainability information and certification can be holistically appreciated, we’re increasing confidence amongst architects and designers that they are making the greenest choice possible, in line with the requirements of their project brief. Working closely with academic institutions, market leading suppliers, designers and developers we’ve created a backend tool which adds tangible value to the material selection process.”

Source: www.lathamtimber.co.uk/about-us/ carbon-calculator

According to the Construction Industry Training Board, the sector will need over 216,000 new workers by 2025 to meet growing demand. To help tackle this problem, TopHat will offer a range of opportunities and shift patterns for new joiners from all socio-economic backgrounds – including part time and flexible roles. Internal learning platforms to enable skills development across a range of construction and manufacturing profiles - including lean, digital, engineering and construction – will also be developed. Women still make up only 11% of the UK’s construction workforce. By 2023, TopHat aims for women to account for 40% of its workforce, making it the top-rated construction firm for gender balance.

Jordan Rosenhaus, Chief Executive at TopHat, added: “Lucy’s appointment comes at a time when we’re really accelerating the growth of the business as we continue to increase our pipeline of developments across the UK. As we look to progress with a longterm strategic vision of growth, TopHat will benefit from Lucy’s industry and commercial experience that will help us to continue revolutionising housing delivery across the UK.”

Source: www.tophat.io

Bellsmyre Regeneration Sees First Tenants

The major regeneration scheme at Bellsmyre, Dumbarton is taking shape with four families moving into their new homes and the council giving the green light for the next phase of the major scheme, partfunded by the Scottish Government, to improve the housing provision in the area.

The first tenants have been handed keys to their new homes at Muir Road, for Caledonia Housing Association. A further 62 homes will be completed by May this year providing much needed, high quality and affordable housing for the area. The brownfield site along Muir Road is the first phase of Caledonia Housing Association’s regeneration for Bellsmyre. The new development is designed by ECD Architects and constructed by CCG (Scotland). The new homes constructed at Muir Road will be a mix of houses and flats with one, two and three bedrooms to cater for a wide range of families and individuals. There will be a further 40 two and three-bedroom houses, and 22 one and two-bedroom flats.

Construction at Muir Road used modular offsite building methods allowing for enhanced levels of performance and quality for the newbuild construction. It also limits the need for heavy machinery on site and reduces work force traffic resulting in less disruption for tenants moving in and for the community nearby. All the homes

UK INDUSTRY NEWS

at Muir Road are finished in a grey multi-tone textured brick, with contemporary grey window frames. When complete Muir Road development will include areas of open space with a dedicated area with children’s natural play equipment, benches and landscaping.

Andrew Kilpatrick, Director of Assets, said: “Creating new homes at Muir Road is a real milestone and we will be handing over keys for the much-needed affordable housing, from now until the development is completed in the early Summer. Many of the new tenants moving in have been in alternative decant accommodation for two years, whilst they waited for the development to be completed. We are so pleased we can now welcome them to a high-quality new home.”

Dilveer Kaur Hoonjan, the lead Project Architect, ECD Architects, commented: “It’s great to see tenants now moving into their homes at Muir Road.

We are delighted to receive planning approval with the positive feedback we have received from the community and West Dunbartonshire Council for this project for Caledonia Housing Association. We look forward to seeing the project progress over the coming months.”

The planning permission approval is to build a further 140 new homes and improve community amenities in Bellsmyre, Dumbarton. The ambitious plans for the £40million regeneration including new homes to replace many of the original tenements. Complete, the development is set to be one of the most energyefficient of its kind in West Dunbartonshire with varying standards of build, including operational net zero carbon and the Passivhaus standard.

Source: www.c-c-g.co.uk

Housing Pattern Books Will Transform Affordable Homes Delivery

Advanced Industrialised Methods for the Construction of Homes (AIMCH), the three-year project to support the sector to tackle the UK housing crisis, has arrived at an answer to the UK’s chronic housing shortage. Following 18 months of intense collaboration and research, AIMCH partners Stewart Milne Group (SMG) and L&Q have developed housing blueprints for developers, housing associations and SMEs to bring affordable homes to market quickly and cost effectively.

The affordable housing pattern books, featuring 24 designs, have been created to facilitate the construction of cottage flats, bungalows, semidetached and terraced houses, all of which offer the flexibility to meet planners needs, and to fit in with local character. Designs from the pattern book can also be pieced together to accommodate a range of elevations and streetscapes.

A central element of the type approved housing collections is their use of closed panel MMC timber technology, optimised to meet 55% PMV (Premanufactured Value), a requirement of Homes England grant funding. Their 0.20 U-Value provides a fit-and-forget, fabric first approach to energy efficient building envelope, set to comply with new June 2022 Part L building regulations.

In creating the pattern books, the developers have leveraged learnings from Design for Manufacture

Top Five Housebuilder Bellway Goes Modular

and Assembly (DFMA), Design Standardisation and Product Families (Kit of Parts) and BIM (3D modelling) outputs. AIMCH developers plan to exploit the standard house type pattern books on their own sites, or through strategic partnerships with other developers and clients.

Stewart Dalgarno, Director of Innovation and Sustainability at Stewart Milne Group, and AIMCH Project Director said: “Typically, in the affordable homes sector, design and housing procurement are done on an isolated project-by-project basis, which potentially leads to higher costs, inefficiencies and variability in quality. Because of this, AIMCH sees enormous potential for accelerated use of pattern books in the sector. Furthermore, through

Leading modular housing company ilke Homes has been selected by top five housebuilder Bellway to deliver the FTSE 250 company’s first modular homes. The partnership will see ilke Homes deliver 40 factory-built homes on a site in Milton Keynes. Branded Tattenhoe Park, the wider scheme will comprise 160 homes built from steel and timber framed homes as part of a pilot project being led by Homes England.

Homes England’s pilot projects are delivering 1,800 homes across the country as part of a study into the benefits of MMC. These include improved quality and energy efficiency, and a reduction in construction waste. A recent report from the House of Lords’ Built Environment Committee suggested factorybuilt housing will be instrumental in speeding up development across the UK.

It is the first time ilke Homes and Bellway have partnered to deliver homes in the UK, with the modular housing pioneer already having signed several other deals with some of the country’s biggest house builders. ilke Homes will be delivering a mix of two, three and four-bedroom homes for Bellway, for both affordable and open market tenures.

endorsement from regulators, funders, and insurers, AIMCH believes that housing pattern books and standardised products will become commonplace in the affordable housing sector.”

Wayne Hill, Production Strategy Director at L&Q added: “L&Q is proud to be leading the way in the adoption of offsite technologies in the affordable housing sector. These developed approaches offer a clear way for housebuilders, housing associations and local authorities to adopt MMC methods, and the efficiencies which come with them, to build homes for those who need them the most.”

Source: www.aimch.co.uk

Tom Heathcote, Executive Director of Development at ilke Homes, said: “Proof of both concept and delivery means that ilke Homes has become a partner of choice for the UK’s biggest house builders. It’s great to partner with Bellway Homes at Tattenhoe Park, a truly innovative, Homes England-backed scheme that is aiming to demonstrate the benefits of MMC by collecting granular data on the performance of our own precision-engineered homes.”

Paul Smits, Managing Director at Bellway Northern Home Counties, added: “Bellway is pleased to confirm this partnership with ilke Homes to deliver our first modular homes at Tattenhoe Park. We have developed our plans with ilke’s input throughout, and their expertise has accelerated our learning around their products and processes. Now contracts are signed, we look forward to seeing these new homes being manufactured by ilke Homes and preparing to install the units at Tattenhoe Park.” Bellway is due to start work on site in March, with ilke Homes expected to deliver the first homes in August.

Source: www.bellway.co.uk

www.ilkehomes.co.uk

STILL SO MUCH TO BE DONE

Established in 2000, FSi has grown from strength to strength to become the biggest manufacturer of passive fire protection in the UK but there’s still so much to be done.

In the 1980's, fire-related deaths were higher than 1000 per year but have come down dramatically over the last 4 decades to under 300 per year. This is due to several factors such as the Furniture and Furnishings (Fire safety regulations 1988), The smoke detectors act of 1999, The Regulatory Reform (Fire Safety) Order 2005 along with massively improved education and fire warden training plus the decline in smoking.

However, there’s still so much to do, not only in new builds, but existing buildings nationwide such as schools, colleges, universities, hospitals, care homes, hotels, and high-rise accommodation.

These existing buildings require widescale "de-risking " with all the challenges that this presents, as some date back to the 1600's for example, older universities, often with high student occupancy.

Even with fire-related deaths in decline, we’re still faced with £billions in cost to the economy through loss, damage, and refurbishment. After the devastating impact and loss of life with Grenfell Towers, we need only to look at the winter of 2018, which saw a huge car park in Liverpool destroyed, then two major hotels, a large student accommodation in Bolton and a Cheshire care home razed to the ground in the summer of 2019.

With the professional support of the FSi team, we can carefully guide PFP installers to compliancy, meeting specifications and, proposing the best solution.

For more information, please call 01530 515130 or email sales.fsi.uk@etexgroup.com.

Ade Aynsley BA (Hons) DipM PGCE

The module allows loaded wall or floor fire resistance test results to be extrapolated to walls or floors with certain variations in their specification. SCI have designed the module to make the calculations easier and quicker to perform, but still providing the trusted results you would expect with SCI’s experience. This module compliments and extends the capability of the widely recognised Tekla Tedds Software and has credibility with checking Authorities and Warranty providers due to its SCI Provenance.

www.steel-sci.com

SCI’s Tedds Module: SCI P424 – Method for Extending Fire Test Results. This latest module implements the procedures described by the SCI publication “Fire Resistance of Light Steel Framing”, (P424)

Surrey Low Carbon School Celebrates Modular Milestone

A significant milestone in one of the DfE's ‘Low Carbon Pathfinder' projects has been reached with an end-of-module-installation ceremony taking place at Merstham Park School, near Reigate in Surrey.

The ceremony was attended by representatives from DfE – including Paul Mustow, Divisional Director for DfE – GLF Schools and the project’s principal contractor, McAvoy. With final fit-out and site works now underway, the multi-million-pound school that will provide learning space for around 900 pupils is scheduled for final handover in time for the new academic year in September. The new two and threestorey building will replace the school’s temporary facilities that have been in use since the school's opening in 2018 and will provide pupils with highquality classrooms, play space, a dance studio, an all-weather sports pitch, and a sports’ hall.

The ‘Low Carbon Pathfinder' school for pupils aged 11-16 seeks to minimise energy usage by implementing the ‘Be Lean, Be Clean, Be Green' energy hierarchy which focuses on reducing the demand for energy at source through passive measures before considering efficient systems and renewable technology. The building will run mainly on electricity and will feature roof-mounted solar panels. The biophilic design approach encourages pupils and staff to engage with nature, trees will be positioned around sun boundaries to create an inviting environment and assist with cooling.

All the school accommodation, apart from a new sports hall, has been manufactured in a factory-

controlled environment at McAvoy's state of the art facilities. Over the course of six weeks McAvoy's expert team craned 178 modules into place. Its onsite team will now carry out final ground works and fit-out in advance of official handover later in the year.

McAvoy's Contracts Director, Martin O'Neill said the adoption of offsite construction, as opposed to more traditional build methods, had major advantages for the DfE, school and its local community. “In this instance, by choosing an offsite solution the Department was able to commit to delivering a high quality, low carbon school within a much shorter time frame than would have been the case otherwise. In addition, with much of the school structure being manufactured offsite, both the schools' pupils who are studying in temporary accommodation and the local community will be exposed to significantly less site traffic movements and disruption. We are delighted with the progress so far and we are looking forward to seeing the pupils being able to enjoy their new school having been in fully temporary accommodation for more than two years."

Ron Clarke, Chief Executive Officer at McAvoy, said: “This will be an exceptional school building that will meet extremely high environmental standards. We are honoured to have been selected by DfE to drive forward its commitment to low carbon schools within the context of this Pathfinder Project.”

Allan Thomson, Project Director at DfE added: “I am delighted that we have reached this significant milestone. It is testament to the hard work and

collaborative approach adopted by everyone involved, from the DfE project team and our technical advisors (MACE) to the McAvoy team and of course the GLF Trust who will be the ultimate end-user of what will be a wonderful teaching and learning environment that will benefit not only the staff and pupils but also the wider community for years to come."

Jon Chaloner, CEO of GLF Schools is delighted that the new building has been built to high environmental standards championing the DfE's long-term commitment to low carbon schools, saying: “It has been a pleasure to watch the build grow and develop and the highlight has been to finally tour the site and understand how it will look this summer when it's finished. With its state-of-the-art facilities, this new build will create wonderful opportunities for our students at Merstham Park and our other local GLF schools, Lime Tree and Merstham Primary who will be able to share, along with the wider community.”

McAvoy Group is also finalising installation work at Porton Science Park where a new two-storey, 3,716sqm building will provide SME research companies, including ‘start ups’, with opportunities for collaborative working, utilising a mixture of serviced labs, office facilities, conference and meeting rooms. The new facility will sit adjacent to Porton Down –home to Public Health England and the Ministry of Defence Science and Technology Laboratory. The building is scheduled to be ready for use in Summer 2022.

Source: www.mcavoygroup.com

UK INDUSTRY NEWS

Final Modules for King’s College Hospital

Premier Modular, has installed the final modules for a new 3,450sq m outpatient services building at King’s College Hospital in London, achieving a major milestone in the build programme. The £21million contract is Premier’s largest single offsite healthcare project in its 65-year history, which is being delivered with its construction partner Claritas.

133 steel-framed modules weighing up to 11.5 tonnes each have now been installed using a 500-tonne crane in a complex operation. This involved careful logistics planning to maintain access through the hospital campus at all times, and to co-ordinate cranage to avoid any disruption to the helipad and air ambulance helicopters. The site is highly constrained with roads to three sides and is immediately adjacent to another hospital building.

When finished later this year, the building will provide 48 consulting rooms and eight procedure rooms for a range of outpatient services, including dermatology, rheumatology, neurosciences, as well as other aspects of surgery and therapy. Commenting on the completion of the building installation phase, Jon Wardle, Chief Executive of Claritas, said: “The whole project team, the Trust and our delivery partners have done a tremendous job of installing this large-scale building on an incredibly constrained site at the heart of this major

hospital. Everyone involved worked hard to ensure the installation phase was completed as smoothly as possible.”

All the modules have now been installed and connected. Stage two of the construction programme will involve final fitting out and completion of the external façade, including a feature entrance with double height glazing to provide high levels of natural light for the reception and waiting area. The project was procured through the Crown Commercial Service framework and is designed by P+HS Architects. The M&E specialists are TClarke.

Dan Allison, Divisional Director at Premier Modular, said: “When you have a hospital site as restricted as this one,

it is easy to see how offsite construction really comes into its own. We are reducing the amount of plant, materials, and vehicle movements to site by moving as much work offsite as we can. And by constructing the building structure in the factory while the foundations were progressed on site, these new hospital facilities will be brought into use at an earlier stage, to the benefit of patient care.”

Bespoke building solutions can be developed for highly constrained hospital sites and are manufactured with zero waste to landfill. Existing facilities can also be expanded easily, safely and cost effectively, both vertically and horizontally.

Source: www.premiermodular.co.uk

Setting the standards for offsite fastening

BeA your partner for offsite timber and light gauge steel frame construction

Across Europe and worldwide, BeA’s fastening technology, tools and consumables are the trusted choice for some of the biggest and best known names in offsite timber and light gauge steel frame manufacturing. BeA manufacture an extensive range of market leading choice of fasteners, nails, staples and tools.

We offer customers:

• An unrivalled range of manual, semi-automatic and fully automated fastening solutions.

• Using industry leading quality controls, BeA meet or exceed standards such as Eurocode 5.

Reliable products, competitive prices and the kind of service and delivery you can depend on from BeA.

01482 889 911 sales@uk.bea-group.com visit our website www.bea-group.uk

THE POWER OF FASTENING

Trimble Announces Latest Version of Tekla® BIM Software

Tekla's latest software automates workflows and ensures communication between project participants at all stages. Tekla Structures and Tekla Structural Designer, which are based on Trimble's workflow streamlining technologies, now offer a dynamic embodied-carbon calculation function for design and drill-down processes using the Embodied Carbon Calculator. This visual and dynamic calculation tool allows users to assess the environmental impact of their design decisions directly quickly and accurately in Tekla software.

Design engineers can use the calculator to compare different design options and their associated carbon loads. Environmental professionals on project teams can also use the specially designed OneClick LCA carbon dioxide emission calculator integrated into the Tekla system to produce environmental product declarations (EPDs). Combining ordered Tekla software data with One Click LCA data and the extensive EPD database allows you to calculate the embodied carbon emissions for the materials used in production, down to each nut, bolt and rebar throughout the entire lifecycle.

The 2022 version of Tekla Structures improves the entire workflow – from design to production – with built-in intelligent functions for creating production drawings, and reduces the time spent creating and editing drawings. To produce concrete parts, the new Tekla Structures system offers reinforcing assemblies. The new feature, used primarily in Manufacturing and Assembly Technology (DfMA), strengthens Tekla's portfolio of tools for automated element manufacturing. Another new feature in Tekla Structures 2022 is the advanced Embodied Carbon Calculator, which allows Tekla Structures users to perform dynamic calculations and visualize the CO2 implications of design decisions.

The Embodied Carbon Calculator, which was already introduced in Tekla Structural Designer in 2021, now offers improved viewing, reporting and sharing of carbon emissions. Using Tekla Structural Designer,

design engineers can calculate the embodied carbon in various versions at the design stage, optimising materials for designing structures with low carbon emissions. Information is easily transferred from the software by exporting reports, charts and data.

To improve the interconnection of design and detail processes, Tekla Tedds 2022 software makes it easy to share design information and documentation through the Trimble Connect™ collaboration platform. The latest version also includes new calculations and updates to existing ones for faster and more reliable design of structural elements.

The Tekla PowerFab 2022 steel fabrication management software suite solves common engineering problems, with improved management of layout and materials for joining and splitting elements. Thanks to simplified system implementation, new customers can seamlessly migrate from their current production management information system (MIS) on Tekla PowerFab. This helps to avoid tedious manual work and allows you to confidently use the new system, since data from past projects is automatically saved as needed. The software also improves monitoring and control thanks to the new delivery calendar in the Tekla PowerFab Go web application.

Michael Evans, Senior Commercial Director of the Trimble Group, said: "Tekla software continues to change the way we work in the construction industry. Our solutions organise information about construction and facilitate access to such information for all project participants, which allows us to optimise the cost of materials and the use of human resources. Thanks to continuous improvements and the high intellectual capabilities of the software, as well as the implementation of solutions for the sustainable development of the construction industry, we occupy a leading position in the supply of BIM technology platforms in the modern market.”

Source: www.tekla.com/2022

HE Simm Group Create Pinnacle Offsite

The HE Simm Group – one of the UK’s leading engineering and services businesses – has invested £1million in a new-state-of-the-art 21,000sq ft facility, to build on its ever-expanding order book for MEP prefabricated solutions.

To be known in the marketplace as Pinnacle Offsite, the business, which is being led by Ernie Price, a prefabrication specialist with over 20 years’ experience, has been launched off the back of continued and sustained demand for prefabricated solutions from its UK-wide customers. The facility, based in Walsall in the West Midlands is already working on the production of prefabricated solutions for customers the length and breadth of the country. Solutions include the manufacturing of packaged plant rooms, plant skid modules, MEP lateral and riser modules and prefabricated utility cupboards.

Commenting on the news, Gareth Simm, HE Simm Group’s CEO, said: “This is a major milestone for us. As we have grown, we have seen a distinct rise in demand from our customer base for prefabricated solutions. Our investment in the facility and in the Pinnacle Offsite business overall proves our commitment to this offering, which will enhance what we can provide as a leading MEP player. Ernie is a specialist in this field, and we have no doubt that he will make a real success of it. He will work closely with Greg Simm and Marcus Wallis – Managing Directors of our Engineering business in the North and South respectively, to make sure that our bids always comprise, wherever possible, a prefabricated solution.”

Greg Simm, the Executive member of the Group responsible for Pinnacle Offsite, added: “This really is very exciting. We’re delighted with the investment we’ve made, with the facility that’s already up and running, and with the team we have in place. We’re looking forward to becoming well known in the marketplace for our innovation in this area and to growing it over the coming years.”

Source: www.hesimm.co.uk

Timber Development UK Release 2022 Market Statement

Following an extraordinary year for the timber industry, Timber Development UK (TDUK) has released a market statement to provide greater clarity on the current supply and demand situation. The market statement provides a detailed analysis of the past year, looking at the import and price statistics of 2021, as well as how recent events will impact inflationary trends in 2022.

One key takeaway from the statement is that the timber supply chain is resilient with 2021 proving to be a record year for imports despite significant disruptions to the market. Import volumes in 2021 reached nearly 11.7 million m3 – a 15% increase on 2020. This is the largest volume of imports seen in the UK since 2008, reflecting strong demand for timber products.

With another year of significant disruption highly likely due to the invasion of Ukraine and economic sanctions against Russia and Belarus, communication across the supply chain will remain vital. The report considers how the invasion will influence supply, demand and price, and recent market trends, with consideration given to construction forecasts for 2022.

Nick Boulton, Timber Development UK head of technical and trade policy, said: “This market statement provides clarity on what was a truly remarkable year for our industry, as well as what we can expect in 2022.

Willmott Dixon Look to Offsite in Northminster

A landmark £65million high-quality housing and commercial space complex, which is being delivered by national contractor Willmott Dixon on behalf of Peterborough Investment Partnership (PIP), has officially started on-site with a ground-breaking ceremony attended by city leaders.

The new Northminster development will boast 315 units consisting of one, two and three-bedroom apartments, and 37 townhouses. The two ground floor units present leisure and hospitality commercial space opportunities, and residents will also benefit from improved public space at nearby Laxton Square.

Using innovative construction methods to build better, greener and smarter, Willmott Dixon plans to make efficiency savings through pre-manufactured value, which it forecasts will contribute to 63% of the project value. Offsite elements will include a light gauge steel frame, brick slips and the use of bathroom pods, which will help to ensure quality, programme certainty and come with environmental benefits.

Reflecting on 2021, for the first time in my memory we saw timber nearly cleared off the shelves of all merchants.

“I would like to say that we are moving back towards normality in 2022, however, the supply situation remains particularly tricky given continuing labour shortages and high fuel costs. Recent weeks have also seen the awful illegal invasion of Ukraine by Russia which is likely to exacerbate existing supply and price pressures. Yet against this backdrop, timber will continue to play a pivotal role in 2022 as the UK looks to build back better, safer, and greener while achieving net-zero targets. As the only mainstream low carbon construction product, timber will be central in our bid to reduce construction emissions.”

All readers should note that both PEFC and FSC have reclassified goods from Russia and Belarus as ‘conflict timber’. Any goods which had due diligence applied AFTER 2 March 2022 should be considered ‘conflict timber’ and ineligible for PEFC certification and trade. For FSC any goods which were shipped and placed on the market AFTER 8 April 2022 should be considered ‘conflict timber’ and ineligible for FSC certification and trade.

Source: www.ttf.co.uk

www.pefc.org

www.fsc.org

Due to be finished in August 2024, the development, which is, in part, being funded by a £14million grant from Cambridgeshire and Peterborough Combined Authority, will provide much needed high-quality and affordable housing. All homes will be let at discounted rents, set at or below 80% of the normal market rate.

David McCallion, Director at Willmott Dixon, said: “We are proud to be delivering this fantastic ten-storey flagship Northminster development in collaboration with PIP, providing affordable housing stock and valuable commercial spaces to further attract investment into the area. This is such an important regeneration project for Northminster and we are looking forward to working alongside our delivery partners to revitalise the area for residents and the wider community.”

Peter Hiller, Board Member at Peterborough Investment Partnership, added: “This is an exciting day for the city and the beginning of a new era for Northminster. When finished, residents will be able to look out from beautiful apartments and see the spires of Peterborough City Cathedral on their doorstep. They’ll be a short walk from our train station, with great links to the north and south, and an even shorter walk to the excellent bars, shops and restaurants in the city centre.” Willmott Dixon is working alongside project architect Corstorphine & Wright – a partnership that has been successful on several projects across the UK.

Source: www.willmottdixon.co.uk

PRODUCT PLATFORM RULEBOOK

DESIGNING IN CHANGE

Late last year, the Construction Innovation Hub’s Platform Programme published the findings from a series of workshops and development activity. Trudi Sully, Impact Director at the Hub outlines what to expect, with the first draft of the Product Platform Rulebook soon to be published.

At the end of last year, the Construction Innovation Hub’s Platform Programme published ‘The Road to the Rulebook’. Summarising feedback received via extensive stakeholder consultation, this document provided

both an introduction to the concept of platform-based approaches in construction as well outlining a framework, guiding readers as to how to develop and deploy product platforms to meet an aggregated demand.

The creation and release of this ‘Product Platform Development Framework’ is one of several key steps guiding the industry to develop and apply product platforms in the manner driven by government, through policy such as the Construction Playbook and Transforming Infrastructure Performance Roadmap to 2030.

Hot on its heels, the Hub are very soon to release the initial draft of the Product Platform Rulebook for consultation. This Rulebook of open access guidance, key processes and approaches, will be the blueprint for developing and implementing product platforms for current and future market players, with built-in mechanisms for continuous improvement and future opportunities for harmonisation and rationalisation as capability and capacity grows. It is intended to address directly:

• Why: Why do we need a platform approach to construction, what outcomes are we trying to drive and how is policy driving the emergence of product platforms?

• What: What are product platforms, what are their defining features and what are the rules that govern whether something can be deemed a product platform?

Most of the Hub team driving the Rulebook development come from organisations in a competitive market, truly demonstrating the power of 2

• How: Guidance on how to develop a product platform, the key decisions that need to be taken and the key outputs required to demonstrate compliance and to support their deployment on construction projects

collaboration and the commitment of these organisations to work together to overcome common industry challenges for the benefit of all. Furthermore, the Rulebook will be brought to life through relatable and relevant case studies, with contributions from proof of concepts and flagship projects and solutions, such as SEISMIC, Bryden Wood’s Platform II, the Department for Education’s Gen Zero, and ProCure’s Repeatable Rooms.

However, input does not stop there. The early consultations involved 120 different organisations, from government departments, to consultants, contractors, manufacturers and throughout the supply chain.

Once the draft is released next month, another round of consultation will be held to enable further refinement and development with the first edition release scheduled for late summer.

There is recognition that the Rulebook will need to remain a live document, sitting with an impartial custodian, that will coordinate ongoing development by industry contributors as more product platforms are developed and deployed.

Ultimately the Rulebook is designed to support government departments in implementing policy set out in the Construction Playbook and TIP Roadmap - building a strong aggregated pipeline of programmes on which product platforms can be deployed via a disaggregated supply chain - whilst enabling industry to confidently build their capability and capacity in response to the demand going forward.

We can’t wait to share all the hard work when the first, beta edition of the Rulebook lands and hope this marks the beginning of a live and agile resource which can support the rapid emergence of, and continuous improvement in, construction product platforms for generations to come.

PRODUCT PLATFORM RULEBOOK

To find out more about the Construction Innovation Hub Platform Programme visit: www.constructioninnovationhub.org. uk/platform-programme/ 3

Images:

01. The Rulebook will help boost the manufacturing process as a central aspect of product specification and reliability 02-03. Factory precision is the future of a more productive construction industry

WHAT ARE PRODUCT PLATFORMS?

The term Platform is widely used but consistently includes:

• A set of low variety core assets (i.e. components, processes, knowledge, people and relationships)

• A complementary set of peripheral components that exhibit high variety

• Stable interfaces that act as a bridge between the stable core and variable peripherals.

(Source – Network Plus digest)

A Product Platform includes a kit-of-parts, associated production processes, and the knowledge, people and relationships required to deliver all or part of construction projects using a platform approach.

A Platform approach provides the mechanisms to improve productivity whilst ensuring high standards of quality and performance, thus enabling better, faster, greener delivery of our infrastructure needs. The approach encourages innovation and enables market evolution.

DEMAND DEVELOP DEPLOY

Demand: The use of product platforms requires an aggregated demand, which is supported by harmonisation and rationalisation of design requirements across a range of asset types and client organisations. This is done away from the project environment and needs to provide confidence to the supply chain that the solutions they develop will have a market.

Develop: How to respond to an aggregated market demand through the development of a particular product platform which can be deployed across multiple projects and programmes.

Deploy: Approaches for incorporating one or more product platforms in the delivery of a specific project or programme. Shifting, where possible, from design and construction to configuration and assembly.

NEW BRAND: NEW VISION

Elliott and its affiliated UK companies have a new face, new name and are looking towards an exciting future ahead as they unite under the common brand name of Algeco.

The move creates a single, consistent brand across the UK and Europe, to reflect the Group’s position as a global industry leader. Algeco is a longestablished brand in the European modular services and infrastructure industry, originally formed in 1955 providing a strong basis for the single identity, which will facilitate growth in its brand equity and allow greater synergies to be achieved within the Modulaire group. Customers can expect to see a stronger, combined UK organisation as well as more sharing of innovations and resources within the group, and a unified product range available throughout the UK.

“Algeco, is part of the Modulaire Group, Europe and Asia Pacific’s leading specialist in modular services and infrastructure,” says John Campbell, UK Managing Director, Algeco. “It introduced the first stackable modular accommodation in 1965. Throughout the 70s, 80s, and 90s, the brand developed a stream of further innovations that expanded its high-quality modular accommodation from construction into education, health and commercial sectors.

“We have been planning the rebrand to Algeco for some time and it coincides with sustained growth in our UK businesses. At the same time there

1is unprecedented change happening in the way that physical spaces are created in a wide range of vertical markets, driven by climate change, safety and growing user expectations. Adopting a single brand in the UK will create a common sense of identity and purpose for the newly combined UK business.

Integrated product ranges within a single, unified brand

“This rebrand is more than a change of identity. Incorporating three separate brands into one UK entity has also meant business integration. A key element involves aligning the product lines and product architecture to further strengthen our overall offering.

“Elliott Group, Carter Accommodation and Procomm Site Services, are well respected businesses in the markets they serve, and all have strong product line brand names that complement our offer. The Elliott Moduflex system is well established in the site accommodation market. Carter is a leading player in the temporary accommodation hire business with a modern and well-invested fleet. It is well known for its Containex product, which offers quality modular site accommodation. Procomm is a large customer of Carter, which provides obvious synergies. The combined

UK business will be headquartered in Peterborough, Cambridgeshire with a total of 23 site locations throughout the country servicing its portable, modular building and offsite construction hire and sales activities.”

What does the Algeco brand mean to customers?

“The new brand represents our collaborative approach to finding solutions for customers, developing both our products and our people to deliver leading quality service and ensuring the futures of customers, their end users and our organisation are sustainable. The rebrand is a major milestone for the UK business and comes at a time when post-COVID government stimulus programmes, aging building stock and a structural shift towards modular space are driving demand.

“We want to be trusted solutions advisers to the markets we support. By doing that, our goal is to be clear market leader in modular and temporary accommodation. The rebrand will be a journey that opens up opportunities for UK customers as we begin to share ideas and resources. It will see an acceleration of new product development, and we already have some exciting innovations in the pipeline. If you were to summarise the brand it would be that together, we develop sustainable futures.”

A new Algeco website is scheduled to go live at the end of March 2022 when the rebranding process is complete.

For more information visit:

www.modulairegroup.com

www.algeco.be/en

Images: 01. Customers can expect to see a stronger, combined organisation and a unified product range available throughout the UK

ROBERT HAIRSTANS

ADAPTING AND DEVLOPING INDUSTRY 4.0

Professor Robert Hairstans, Director of the Centre for Advanced Timber Technology (CATT) at the New Model Institute for Technology and Engineering (NMITIE) has a deep knowledge and understanding of timber and the offsite sector. How do these fit into the wider requirements of sustainable construction?

project. This is to design a low carbon community building for Growing Local, Belmont Wanderers and NMITE. There are 12 multidisciplinary teams formed for the challenge from across 33 UK universities. These learners will have access to software from project partner organisations which including Trimble, Passive House Planning Software (educational version) and the Alliance of Environmentally Conscious Buildings (AECB) Life Cycle Analysis Software.

improved understanding for learners and industry professionals including insurance and warranty providers. We have a unique position here where we can use the building as a live experiment and tool for information.

Q: Have we reached ‘peak timber’ in the UK? With timber imports at the mercy of global supply chains and the associated costs and risks – can we genuinely grow more homegrown engineered timber?

Q: Due to be in full operation later this year, can you give a brief outline of the ethos and direction of NMITE & CATT?

Robert Hairstans (RH): As the building is being built, we’ve been busy assembling the team, engaging with partners and stakeholders and importantly evolving the educational system via the Timber Technology Engineering and Design (TED) programme of work which is now at an advanced stage. NMITE, Edinburgh Napier University (ENU) and Timber Development UK (TDUK) are the lead partners with a steering committee that represents the sector including the Structural Timber Association, Trussed Rafter Association, Swedish Wood and an industry working group representative of the supply chain to establish the competency framework via Harlow Consultants.

The Timber TED competency framework has been used to inform the educational webinar series of the UK-wide TDUK student design challenge – running in the first quarter of 2022 on the Southside Hereford 1

Q: The formation of a ‘Living Lab’ within CATT sounds an exciting development – what will it offer and deliver for those seeking a career in timber design?

RH: We want the building itself to be an educational toolkit. A ‘Living Lab’ creates the necessary conditions for research to be undertaken and innovations created and validated collaboratively in multi-contextual, empirical real-world environments –and all enabled by digital approaches. This concept – including connectivity to other partner living lab projects – will include in-situ measurement of thermal, acoustic, and structural performance via thermocouple, accelerometers, strain gauges and other embedded sensors, with feedback loops to digital models for performance evaluation.

We want to engage the sector with the building and determine opportunities for collaboration on the Living Lab approach. We are working with Stora Enso – the cross laminated timber (CLT) supplier of the building – on the application of 48 sensors to collect data with an emphasis on moisture management. We want to dashboard this information and use it for

RH: According to ONS data, we have around 3.23 million hectares of woodland in the UK covering around 13% of land, and while each year, all timber suitable for harvesting is processed and used for a range of purposes, we remain the secondlargest importer of forestry products, behind only China. The UK currently produces approximately 3.4 million m3 of sawn softwood per annum – 30% of which is used for construction. There is therefore scope to grow more and as well as enhance our current use. This is not to mention the timber that can be reclaimed and upcycled – there is huge potential to do a lot more.

Historically, timber grown in the UK has been used mainly for non-structural applications such as fencing and pallets, as well as repair, maintenance, and improvement activities. But continued research is proving the potential for the use of homegrown, engineered timber to create the fabric and structure of buildings. There are several advantages to using engineered timber over more carbonintensive traditional building materials – for example, buildings are lighter and have a reduced gravitational load, typically weighing 20% less than concrete. For those that want more info I would highly encourage monitoring

the outputs of Construction Scotland Innovation Centre led and Innovate UK funded Transforming Timber Project (see link below).

Q: Embodied carbon seems to be the new battleground and area of study. How can this be quantified, interpreted easily and thereby reduced across the built environment?

RH: Natural, renewable materials have significantly lower levels of embodied carbon, particularly when compared with materials like steel and concrete. Think of it this way, a 10,000m3 per annum CLT plant, would sequestrate 6,760,000kg of carbon dioxide (CO2) from the atmosphere assuming –676kg of CO2 per m3 will be stored after the production process. A recent study also estimates 50 Mt greenhouse gases (CO2e) in up-front avoided emissions, without considering any carbon sequestration and storage potential offered, would result from substituting concrete floor slabs with timber in steel building frames for the next 30 years.

The embodied carbon of a house constructed using offsite panelised timber frame (with the majority embodied in the concrete substructure) is approximately half of that using traditional masonry forms. However, whilst recognising the environmental credentials of timber relative to other construction materials, it is necessary to ensure theories of circularity are applied to ensure maximum value return from the resource, and the impact of other associated activities as part of the dynamic process to delivery utilising the five capitals (manufacturing, financial, natural, social, human and natural) model.

Understanding of this is critically important given we spend 80-90% of our time in the built environment and construction is a major contributor to climate change with buildings and construction together accounting for 36% of global final energy use and 39% of energy-related carbon dioxide (CO2) emissions. The utilisation of timber, a naturally renewable carbon sequestering resource, for construction delivery can produce low energy buildings (employing a fabric first approach) efficiently with enhanced levels of productivity and minimum waste.

ROBERT HAIRSTANS

Q: What core changes in behaviour and specification can architects and structural engineers do to help tackle climate change and provide energy efficient housing?

RH: To reach net zero by 2050 the culture of construction requires to change and become more collaborative. This requires improved levels of human capital that is underpinned by skills. Increasing the use of environmentally sound biogenic and ecological construction materials such as timber, will need to be based on a holistic value proposition and corresponding knowledge sets (productivity, environmental and social impact, cost and building performance over time).

The educational approach of NMITE is to apply a student-centric learning methodology with a curriculum fuelled by real-world challenges, meaning that the approach will be distinctive in the marketplace and will attract a different sort of engineering learner. The mission statement of CATT is to “stimulate collaboration across the

industry both vertically (seed to end product) and horizontally (architecture, construction, digitalisation) as a common theme together with showing a wider audience how rewarding a career in timber can be.”

Q: Industry 4.0, digitisation and all the technical wizardry that it entails – how important to offsite construction and attracting new entrants into the sector are these new tools?

RH: Industry 4.0 (the fourth industrial revolution) is digitisation where the Internet of Things (IoT) enables digital connectivity between everyday objects. Over the next decade this level of connectivity will accelerate, with assets becoming increasingly more ‘intelligent’, presenting opportunities for innovation, creativity and transformation in the built environment. Industry 5.0 personalisation is the next step, with the collaboration of human skills and digitisation. Workers in Industry 5.0 will be upskilled to provide value-added tasks in production, leading to mass customisation and personalisation for customers.

ROBERT HAIRSTANS

The pre-manufacture of construction products can range from component based sub-assemblies manufactured offsite to volumetric systems with high levels of enhancement offering turnkey solutions. Other industrialised options include near to site pop up factories or on-site precision manufacture. These approaches require the utilisation of CAD/CAM combined with CNC machines hence the importance of digitisation and digital skills. These approaches and concept will of course attract new entrants as this is a shift away from the preconceptions of the traditional construction sector and is a move towards a cleaner, safer working environment.

Q: Improving productivity is a concern across the construction sector and the UK generally – how can factory-based manufacture improve that?

RH: The utilisation of timber with factory based and precision engineered approaches offers significant benefits when consider the productivity challenge and levels of on-site waste – construction and demolition waste (CDW) accounts for more than a third of all waste generated in the EU. A Design for Manufacture and Assembly + Disassembly and Reassembly (DfMA+d and R) approach ensures the regulatory lifespan of a building (60 years) is significantly exceeded through the recycling and reuse of structural timber at the end of its standard lifecycle, locking up the carbon for longer. This standardised, mass customisation approach (customising standard components to meet with client requirements) also supports significant flexibility and adaptability when considering

the redesign and re-engineering of buildings whilst in use.

The utilisation of timber and biogenic delivery of the built environment has been evidenced to be the most environmentally sound approach when adopting DfMA+d and R approaches (avoiding landfill) given 90% of combustion emissions could potentially be captured using bioenergy with carbon capture and storage (BECCS) at absolute end of life. Modularity of systems also require more upfront design, the utilisation of a standardised approach as well as the utilisation of digital design. All of this lends itself to the above.

Q: Precision-engineered timber such as CLT and modular offsite systems are one of many options available to ‘unlock’ net zero housing – can it deliver more affordable homes as well as private residential newbuild?

RH: Timber should be top of the list for built environment delivery given its environmental credentials and I would therefore argue that that advanced timber technologies available can now respond to the varying needs of the sector from restoration, retrofit to newbuild solutions (domestic, non-domestic including educational, healthcare and industrial buildings) and infrastructure (bridges, electricity transmission towers and wind turbines).

The array of products and systems available is vast from dimensional timber, engineered products, composites and mass timber systems utilising glue, mechanical and moisture movement forms of fixity. Further, relative to end use and durability

classification (internal or external environment) or associated risk of fire there are varying forms of treatment including heat modification, acetylation and fire retardants. Digitisation combined with modern manufacturing approaches is unlocking the potential of these products and how they can respond to the given context.

Q: Looking ahead – can offsite construction in all its materials and systems – help deliver better circularity and achieve the complex 2030/2050 net zero targets everyone hopes for?

RH: Yes, if the emphasis is on biogenic offsite construction whereby there is a convergence of the renewable resource (forestry, woody biomass and naturally replenishable) and construction sectors to enabling the sustainable manufacture of the built environment. The approach will require to harness digital technologies and be capable of evolving to meet the needs of future generations without impinging upon available resource whilst offering a better quality of life aligned with the UN’s Sustainable Development Goals.

By increasing the use and value of UK grown resource and establishing more sustainable forestry in the UK a seed to building supply chain will be created stimulating economic growth providing jobs and wealth creation in remote and rural communities, instigate start-ups and secure the longterm success of currently established organisations by enabling scale in the market. This will ensure a resilient UK construction sector that is less reliant on non-renewable resources and correspondingly a major contributor to the climate change.

For more information on the work of CATT and NMITIE visit: www.nmite.ac.uk

For more on the Transforming Timber Project – From Forest Floor to Built Environment visit: www.transformingtimber.co.uk

Images:

01. Professor Robert Hairstans, Director of CATT at NMITIE

02. The new CATT building is due for completion in July 2022 and will house studios, workshops and the Living Lab

03. The key drivers of offsite manufacture

04. On show at COP26 – SNRG, Scotland’s first homegrown mass timber volumetric home

Structural Post Connection, Evolved.

Introducing the new PBWS single piece post base for post-to-concrete connections. With the same load-rated capacity as a standard post base, the unique folded build uses 45% less steel, making it better for the environment and easier to handle. And our innovative ZPRO coating provides the same protection against the elements as a hot dip galvanised coating, but with a neater, shinier finish.

Extending the life of outdoor structures, economically. For

SPACESAVING SOLUTIONS

How can pod and modular bathroom manufacturers ensure efficiency and cost savings across bathroom projects without compromising on space or style?

The prominence of bathroom and washroom spaces continues to grow. In residential markets, the bathroom is one of the most important places in the home to switch off from our ‘always-on’ world. Likewise in hotels, bathrooms and washrooms provide the ultimate place of escape and can be a key part of the guest experience. Good design, therefore, has never been more important.

With customers increasingly looking for cost-effective and complete bathroom packages that boast both quality and design excellence, Geberit’s range of space-saving ceramic and bathroom furniture offer pod and bathroom manufacturers a world of design possibilities for any budget or project.

Wall-hung Sanitaryware

Wall-mounted furniture and ceramics, which create the illusion of ‘floating’ above the floor, can offer a space-

1saving solution that opens up the space and creates a streamlined design. The premise is simple. Wallhung toilets are made possible in bathrooms thanks to the inclusion of quick and affordable pre-wall frame systems, such as Geberit Duofix. By concealing the cistern behind a stud wall, a wall-hung toilet reduces the outward projection of the ceramic. In smaller pods, opting for wall-hung ceramics can make a real difference –the ability to conceal the cistern and lift the toilet’s footprint off the floor can make even the smallest of bathroom spaces instantly appear bigger. Servicing and access to the cistern is also made easy via the flush plate.

Commercial Benefits

Opting for wall-hung sanitaryware can also offer operational benefits across commercial projects. Lifting the toilet from the floor makes maintenance and cleaning much easier, helping reduce dirt and dust accumulation – in turn,

this can help commercial customers reduce any associated staffing and maintenance costs. With more than 10 models available, Geberit’s Duofix wall-hung frame system, together with the wide range of wall-hung ceramic furniture, pod and bathroom manufacturers will find a wall-hung solution for any project.

Back-to-Wall Solutions

Back-to-wall toilets offer another space saving option for modular and bathroom pod manufacturers. Instead of installing a wall-hung frame, the WC stands on the floor with the cistern is concealed inside the wall or furniture. These designs, just like wall-hung, are space-efficient by reducing the outward projection of the ceramic and offering a streamlined design. Both Geberit’s wall-hung and back-to-wall ceramic ranges boast features such as soft closing seats, water saving flush and Rimfree pan for easy cleaning.

Slimline Ceramics

Alternatively, opting for simple, slim design solutions can create valuable space on a bathroom project and unlock value. Geberit’s Selnova Compact and Renova Plan series, for instance, offer a suite of compact and slimline furniture options, including short projection WCs and smallerdepth basins. Both ranges also incorporate several smart storage solutions like vanity units, tall shelving and mirror cabinets, helping add value and design appeal to the project.

Putting its customers first, Geberit’s dedicated OEM team works closely with manufacturers, applying their product know-how and technical expertise every step of the way.

For more information visit: www.geberit.co.uk/prefab-washrooms

Images: 01. In smaller washroom pods, opting for wall-hung ceramics can make a real difference

GEBERIT PREFABRICATED DRAINAGE SERVICE

RIGHT FIRST TIME

Prefabricated drainage is the sensible choice for tall buildings, providing a fuss-free solution which improves efficiency without compromising on project cost or quality.

Geberit’s service combines the quality you would expect from a true market leader, with a real focus on customer service from start to finish. We’re proud to deliver a collaborative approach which helps our clients to overcome their challenges through shared designs and on-time deliveries.

geberit.co.uk/prefab

CAN VOLUMETRIC MANUFACTURED BUILDINGS DELIVER A NET ZERO FUTURE?

Is the road to a net zero future a well mapped out route or is there uncertainty along the way? Richard Hipkiss, Development Director of the Modular and Portable Building Association (MPBA) makes the case for volumetric buildings shaping a more sustainable future.

Since the government amended the Climate Change Act in 2019 to commit the UK to achieving net zero carbon emissions by 2050, the construction industry has been confronted with the need to decarbonise.

According to the World Green Building Council, construction and buildings in use are responsible for 39% of all carbon emissions in the world. This is broken down into two elements with 11% being linked to the manufacture of materials and construction processes known as ‘embodied carbon’ emissions and 28% associated with ‘operational emissions’ caused by heating, cooling and lighting systems when a building is in use.

The challenge is therefore two-fold. Whilst there has been a drive to reduce operational emissions through the implementation of government legislation such as the changes to Part L of Building Regulations to improve the building fabric – little has been done to address the carbon inefficiencies in the construction process.

It is now established that volumetric modular approaches are a game changer for the construction industry –reducing build times whilst increasing quality, productivity and safety. But what is not so widely understood is that compared to traditionally built projects it is much easier to control energy use in factory settings than in an open construction site. On average 67% less energy is required to produce a volumetric manufactured building and up to 50% less time is spent onsite, resulting in up to 90% fewer vehicle movements which again reduces carbon emissions.

Volumetric manufactured buildings are digitally designed and virtually tested before they move onto the manufacturing phase. This process eliminates waste and achieves highly accurate and airtight building envelopes designed and built to higher sustainability requirements.

For more information visit: www.mpba.biz 1 2

Unlike factory manufactured buildings, there is significant evidence that traditional construction methods do not produce buildings that perform as well as design expectations and there is a void between anticipated and

actual in-use performance. Findings from studies such as PROBE (Post Occupancy Review of Buildings and their Engineering) reveal that actual energy consumption in buildings is often as much as twice of that predicted in the design.

Not only is the actual construction of the building ‘greener’ but volumetric manufactured buildings are also more energy efficient – reducing primary energy requirements and in-use operational emissions during the lifetime of the building. As the construction sector develops to meet changing government strategies, I firmly believe the upward trajectory of volumetric modular buildings will continue as the benefits begin in the factory, continue to the construction site and last through the lifetime of the building.

Images:

01-02. All volumetric modular buildings from TG Escapes are net zero in operation. The use of timber and biophilic principles delivers spaces which enhance learning outcomes and support well-being

MODULAR METHODS REALLY DO MATTER

The Modular Matters conference and exhibition returned for its fourth year as a two-day event on 15 & 16 February 2022 at the National Conference Centre (NCC), Birmingham. What went on and what were the key messages?

Carbon Reduction Must Happen

Modular technology is ever evolving and to help keep pace with this fastmoving sector, the Modular Matters event demonstrated how to tackle industry challenges through a range of project case studies, and expert insight into the future of construction. These events represent a great opportunity to gain industry intelligence and network with those who are at the forefront of the volumetric modular sector.

On day one – Tuesday 15 February –delegates heard in expert detail how volumetric modular technology is being used across a range of vertical construction markets including commercial, education and healthcare. Day two – Wednesday 16 February –focused on housing projects including private residential, build to rent and affordable housing: collectively creating huge interest in offsite technology. Across both days a range of issues were raised and discussed with carbon reduction probably top of the agenda.

Peter Rankin, Head of Energy and Environmental Standards (Building Regulations) for the Department for Levelling Up, Housing & Communities, delivered his keynote presentation: “Our journey towards net zero – what it means for the offsite sector” at the start of day one. With building regulations updating in June, he gave an indication on what to expect in the drive to create more energy efficient homes and how the new regulations will help move the country to meet its net zero targets. New regulations will include a 30% carbon reduction for newbuild homes from current standards, with other new buildings, including offices and shops, expected to reduce by 27%.

Following Peter, Richard Hipkiss from the Modular and Portable Building Association (MPBA) highlighted the facts surrounding volumetric design and how a “confused construction supply chain” could be slowing progression, while MPBA and Wernick’s Andy King offered a manufacturers perspective on the complex “lexicon of carbon”, building lifecycles and the pressing needs to act in a more circular fashion – when consultants request embodied carbon

figures do they all know what they are asking for? Can volumetric modular be benchmarked for embodied carbon in the same way as traditional building materials?

The next session showcased some award-winning projects including Dinton Activity Centre with HLM Architect’s Alex Pullins. Paul Ruddick, Chairman, Reds10 outlined the company’s work on the Imperial War Museums’ new London staff hub. Paul discussed how the project pushed design to a higher level and truly showed the quality that can be achieved when architecture is embedded in the modular construction process from the start.

The afternoon session opened with Scott Tacchi, Head of MMC for the Department for Education who delivered his keynote presentation:

“DfE MMC – Following 6 years of MMC School delivery the observations are….” which looked in detail at the DfE’s MMC delivery for its school’s programmes. He also gave some context to the rollout of the MMC1 Framework and offered some observations for the future including DfE ambitions to develop standardised

solutions for secondary and SEN schools and the central hosting of a digital twin with cradle to grave data management.

Delegates then heard several case studies including: ‘The Valentine’ a student accommodation building on Gant’s Hill which was presented by Richard Foxley from HTA Design. Andrew Tindale from Hawkins\ Brown and Simon Elliott from Premier Modular co-presented their collaboration on TEDI-London and Emily King, Divisional Director, Spatial Initiative, discussed New Horizons and Southwest Exeter New School – “two examples of a standardised approach with bespoke outcomes.”

Closing day one, Robert Townsend of Wernick Group looked at how healthcare facilities are benefiting from standardised modular design whilst Dean Hill from Thurston Group delivered a case study on their extension for Tameside General Hospital which was delivered in record time to help fulfil patient numbers during the COVID-19 crisis.

Technology, Design & Delivery

Opening day two, a sold-out audience heard from Giles Carter, CEO of ilke Homes, that have quickly become a core business in the modular homes sector and are committed to delivering net zero targets with the ilke Zero and new Zero Bills homes. “It’s an amazing time to be in modular and in low carbon housing,” said Giles. The Zero Bills home come with a combination of three sustainable technologies –solar panels, new battery design for power efficiency and an air source heat pump – to add to a premium fabric first approach.

Another exciting central player in the modular homes market is ‘tech-driven’ TopHat. CEO Matt Evans explained their vision and how its White Road project is a blueprint for housing, with the modular approach and advanced manufacturing are fundamentally changing the way homes are built. “Everyone working on our homes has a task they can master and get better at,” said Matt. This road to quality, reliability and repeatability will ultimately improve growth and productivity.

MODULAR MATTERS 2022

Victoria Moore, Business Development Manager, Volumetric Modular, offered a different dimension to the housing sector, with its response to the homelessness crisis with MODULHAUS™. Designed and developed by VOLUMETRIC™, Victoria gave an overview of the award-winning concept. In partnership with Hill Group, it is providing turnkey solutions to help house some of the 274,000 homeless people in England alone. Using lean manufacturing and DfMA techniques, it provides a safe place to stay but importantly, it offers a ‘key to the door’. Meaning the chance to ‘own’ an address, open a bank account, find a job and be independent.

Following a social/affordable housing themed morning, the programme then turned to focus on build-to-rent projects including Greenford Quay – the UK’s largest purpose designed rental community. Greystar’s Design Director, Neal Shah outlined how the mixed-use scheme used advanced design to produce repeatable rooms and typologies, and highlighted the collaboration required between client, developer, design team, contractor and manufacturer.

Michael Swiszczowski, Director at Chapman Taylor, explained why modular construction is perfect for build-to-rent by showcasing their collaboration with leading global offsite manufacturer CIMC. Chapman Taylor has designed multi-family apartment layouts for CIMC’s patented modular system, which is capable of quickly and flexibly delivering one, two and three-bedroom apartments in an innovative residential format for the UK market.

L&G Modular Homes are now delivering several high-specification projects. CEO Rosie Toogood gave

the delegates an insight into the modular approach they have taken at Waddington Walk, Bristol, and how the modular scheme is helping Bristol on its journey to be carbon positive by 2030. “I’m convinced that modular will change the housing market,” said Rosie.

In the final session, Wayne Yeomans from M-AR Offsite looked back at their modular town house project at Wigan Pier, whilst Andy Cornaby, Managing Director of ModPods International, showcased their Broadlands Housing, Webster Court Project. Both explained their approaches to maximising the potential of scaling up projects and increasing system pre-manufactured value (PMV) before they leave the factory.

Graeme Culliton, UK Managing Director for BoKlok – the joint venture between Ikea and Skanska – finished the day by explaining how affordability is central to its homes concept. Its partnership with TopHat producing timber-based, single-family homes can deliver the same kind of stunning results that are a ‘normality’ across Scandinavian markets.

Two full and thought-provoking days put into perspective how the modular construction market continues to mature and is starting to be a part of: “breaking the cycle at getting worse at building and redesigning and unlocking different supply chain habits.” As many of the speakers pointed out, much of what is built traditionally and inefficiently now must be replicated by low carbon, resilient and standardised offsite manufacture.

For more information on Modular Matters and to view the event photo gallery visit: www.modularmatters.co.uk

SHIFTING PERCEPTIONS ON MMC

Will 2022 be the year we see a real shift toward the use of MMC in residential developments? Tim Reid, Customer Relationship Director, at NHBC sees a range of opportunities ahead.

Recent discussions and anecdotal examples from industry experts certainly suggests that long-held caution about adopting modern methods of construction (MMC) is finally beginning to ebb away. The launch of the new Make Modular trade association in December 2021 underlined the determination within the sector – and among investors –to set about transforming outdated and often incorrect perceptions of MMC. Its members have committed to collectively investing £500million to end the housing crisis and make 75,000 modular homes by the close of the decade, so it will be interesting to see how the association develops over the coming year.

Despite the many potential benefits of MMC, confidence is the deciding factor and has ultimately been lacking – despite ever-mounting evidence of its viability, and a host of successful projects. Perhaps understandably, caution has remained the name of the game, with developers, local authorities and housing associations airing concerns around the popularity of MMC homes and perceived issues with build quality and longevity, and sometimes design and aesthetics. Yet, as the housing crisis deepens and the industry is no closer to meeting the government target of 300,000 new homes per year, attitudes towards MMC are finally beginning to change.

The reality is, MMC has the potential to play a key role in our ability to tackle the housing crisis – not only in delivering single dwellings – but across a swathe of tenures, from Build to Rent and Retirement Living, through to social housing and student accommodation. The fact has become more obvious during the last year as materials and skills shortages have taken their toll.

While there’s no denying MMC projects carry greater risk – and it won’t be appropriate for every development, with some better tackled using traditional methods – we now have the checks and balances in place to limit any risks and the potential benefits do often outweigh the downsides.

MODULAR HOUSING

Provided quality assurance and necessary assessments are in place throughout the development process, the risks in building an MMC residential scheme can now be managed appropriately.

Accreditation schemes like NHBC Accepts are playing an important role in helping to underpin confidence, giving developers and investors the reassurance that the necessary safeguards have been considered, the systems being used are of a high standard and quality and, crucially, are able to stand the test of time. While the accreditation process is vigorous and can be lengthy, ultimately it gives developers, contractors and investors the confidence that quality, design and assembly has been reviewed in detail and appraised thoroughly.

Developers now have a library of NHBC approved MMC systems that have completed stringent assessments, making the process of selecting a suitable system much more straightforward and again helping to reduce risk. So, with the checks and balances in place to manage risk and guarantee quality, confidence is the key to shifting perceptions of MMC long-term. It relies on industry

MAKE MODULAR

4

leaders spearheading the adoption of MMC for new schemes, with new tech and innovation becoming more mainstream.

Convincing investors and funding partners is also a job that remains to be done, potentially freeing up significant capital for large-scale residential schemes across the country, delivering much-needed new homes and supporting the government levelling up agenda. The number of products and systems being submitted for NHBC Accepts is a welcome indicator of the appetite for innovation and the work being undertaken to drive new technology and new possibilities – and with confidence growing in some of the harder to crack corners of the industry, 2022 may just be the year we see real strides in the uptake of MMC.

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

Images:

01. Tim Reid, Customer Relationship Director, NHBC

02. NHBC Accepts is providing assurances of the quality of offsite manufacture 03-04. Make Modular members’ factories can produce a new home every two hours. Courtesy TopHat

Make UK’s new trade body Make Modular, brings together Britain’s leading modular housing manufacturers with a plan to solve the country’s housing crisis by delivering 75,000 affordable high-quality homes before the end of the decade. Members include TopHat, Urban Splash, Ilke Homes, Laing O’Rourke, Legal and General Modular. Make Modular members’ factories can produce a new home every two hours. Make Modular members have already invested more than £500million in new factories, cutting edge processes, and state of the art technology. More than 2,000 new jobs have been created by Make Modular members in the last three years. By moving people offsite and into clean, safe, modern working conditions volumetric can rebuild the construction workforce bringing up to 50,000 new younger people into the workforce.

“Modular housing has grown rapidly in the last few years,” said Dave Sheridan, Chair of Make UK Modular. “The establishment of our own trade body is the crucial next step in this process. As a natural partner to Government to solve the housing crisis, deliver the levelling up agenda, and combat climate change Make Modular will accelerate and advance the MMC agenda through one strong voice rather than a series of disparate ones.”

Make UK, The Manufacturers’ Organisation, is the representative voice of UK manufacturing and represents 20,000 companies of all sizes, from start-ups to multinationals, across engineering, manufacturing, technology and the wider industrial sector. It directly represents over 5,000 businesses who are members of Make UK, from providing essential business support and training to championing manufacturing industry in the UK and the EU.

For more information visit: www.makeuk.org

PLACES FOR PEOPLE REDEFINING MMC

David Robins, Head of Central Technical Services at Places for People, explores just what MMC processes are at hand to housebuilders looking to create new homes at scale –and why he believes a construction mix is the key to the future.

It’s the general consensus that modern methods of construction (MMC) will help the UK sector meet its new homes and sustainability targets. As we strive to create more, much-needed new homes for people across the country, I see a role for both traditional build and MMC. The goal for developers, suppliers and the government, is to create new, sustainable homes and I believe that is achievable if we’re efficiently maximising all forms of construction.

As a sector, we have big targets on the horizon – from the government’s ambition of 300,000 new homes each year, to reducing construction’s impact on the environment. As we work to find ways to achieve these targets, the sector is increasingly looking to MMC. There is a case for homes created in this way: taking away the adverse risks of the British weather and manufacturing homes in a controlled, factory environment helps project schedules remain on course.

There are environmental benefits too. There is less waste when precision engineering a home on a production line rather than onsite, while the scheduled deliveries to site reduce construction traffic. Another benefit is that MMC homes are generally created quicker than traditional builds. Build programmes can potentially be cut by up to 50% with groundworks taking place onsite whilst the home is being created in a factory. There are quality considerations too, with precision engineering making for high quality homes, that are now seen across much of the country.

Learning Curve

As part of our strategic agreement with Homes England, we are committed to delivering circa 6,000 affordable homes over the next 10 years, and MMC is one of the ways in which we will deliver them. We are already onsite using MMC and this year alone we have completed homes at Maple Fields in Bordon, incorporating both

MMC and traditional build to broaden the site’s offering. At St Anthony’s in Newcastle upon Tyne, we’ve just completed the delivery of a further 22 MMC homes.

But while there are positives, there are still challenges to overcome. Fundamentally, this means continued investment in research and development to refine processes, ensuring co-ordination and precision. Companies must also be open to collaboration – we are working with likeminded partners who bring expertise to the table including ilke Homes, and House by Urban Splash –whose modular homes have featured on our Birmingham and North Shields developments.

But it’s not just about finding expert partners, we need to invest in human resource and talent too, upskilling people with the traditional trade skills such as joiners, carpenters and plumbers, but applying them to 1

PLACES FOR PEOPLE

MMC settings. We also must address end-user concerns when it comes to MMC through further investment and by instilling confidence – whether it’s the availability of mortgages on homes created in this way, through to the build’s longevity or how to make modular units adaptable in the future.

Many Methods of Construction

One area I am interested in, is the sector adopting other forms of MMC, many of which are easier to implement and at scale and can have the same impact on sustainability targets.

Modular homes and volumetric technology may grab the headlines, but you don’t need to create an entire home using MMC, instead we should look to bring other forms of construction into the MMC process. We’re exploring this with preassembled doors and composite ground floors which are placed onto a site’s foundations. By fusing construction methods in this way, we can create part-MMC homes that are more thermally effective and have less embodied carbon than a fully traditionally built home.

Moving forward there are ways in which the sector can pull together to deliver new homes, primarily through collaboration, with businesses recognising their skills gaps and reaching out to industry peers to join forces and meet new homes targets. We are always keen to find new land partners or sector colleagues

with whom we can build homes that diversify our portfolio.

The government also has a role to play since it can enable the efforts of developers via the planning reform agenda. In giving the industry more certainty on planning and a more streamlined way of determining applications, this will help us to progress and deliver homes.

For now, we will keep on providing homes using all available construction methods, determining the build process on a site-by-site basis and in line with the needs of local people. New developments on the horizon include two new affordable neighbourhoods with ilke Homes –

307 homes in Burgess Hill, Sussex and 165 homes in Exmouth Junction, Exeter.

The industry must collectively push forward to deliver great examples of high-quality homes, so that we can learn, share our expertise and keep on delivering much-needed new homes across the country.

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

Images: 01-03. Places for People is a leading affordable homes-led placemaker and owns or manages more than 219,000 homes and will deliver circa 6,000 affordable homes over the next 10 years through its partnership with Homes England 2 3

MODERNISING THE UK’S APPROACH TO HOUSING DELIVERY

Construction in general and housebuilding in particular will play a vital role in the UK’s post-pandemic recovery, but as Darren Richards, Managing Director at Cogent Consulting, points out – a strong backing is required to champion the wider use of modular and offsite approaches.

We are seeing more inward investment than I have witnessed in my 30 years working within the offsite arena, but wider acceptance will always be an ongoing challenge and the sector cannot afford to become complacent.

With notable exceptions such as Laing O’Rourke who have genuinely pioneered in the offsite space and put their money where the mouth is, Mace with their ‘jump factory’ experiment and more recently significant ‘declarations of intent’ by the likes of Balfour Beatty with their ‘25% by 2025’ strategy (25% offsite activity by 2025), I would say that many of the

large contractors have not yet truly embraced offsite manufacturing to realise its full potential.

Large trailblazing housebuilders such as Barratt Developments are ramping up their use of offsite technology – now operating at a target of 30% of their output, but that still means that circa 15,000 units per annum will need to be delivered via traditional construction techniques.

Pre-COVID-19 the government laid out stretching targets to develop 300,000 new homes annually but currently homebuilding rates are falling way

short of this. As ever in construction, failure to meet these supply levels is put down to low productivity and labour shortages but this is no longer a valid excuse. Goals laid out in the Industrial Strategy aim to build houses in weeks rather than months. We now have the technology – we can do this.

Modular construction (in all its technology formats) offers so many benefits – with a massive increase in productivity being the most advantageous to the residential sectors together with lower labour requirements.

Then there is the increase in quality associated with factory manufacture, improved material efficiency and less waste going to landfill – all factors that are crucially important to achieving the housing target and to quote the government mantra – ‘build back better’.

I have been around the offsite industry for decades – it is not new, although many seem to believe it is. It has come a long way not only in the development of groundbreaking materials and manufacturing techniques but also digital advancements. Building Information Technology (BIM) as predicted by some, has been a game changer empowering optimal configuration of the offsite solution by digitally connecting multi-discipline teams from the beginning of the concept design to ‘virtual testing’ in preproduction environments right through to the development process and beyond. Forward thinking architects and designers now totally ‘get’ the principles of Design for Manufacture and Assembly (DfMA) and are wellversed in conceiving buildings for factory manufacture and onsite installation or assembly.

In her report ‘Building a Safer Future’, Dame Judith Hackitt highlights the need for a system-based approach with a ‘golden thread’ of information running through the lifecycle of each project. Central to the concept is guaranteeing the traceability and availability of project data and all decisions relating to the design, construction, safety performance and maintenance of the building.

With offsite construction all data can be validated and co-ordinated as part of a structured process, which helps provide accurate and reliable information for clients at the point of handover – BIM is a fundamental part of this activity. It also means it is easier to identify what products and material specifications were used on previous projects should any legislation changes occur. By verifying the materials and products to be used on a construction scheme and by simplifying the on-site process, manufactured homes offer developers an opportunity to avoid many traceability issues.

OPINION PIECE

So, we have the know-how and technology but getting down to the money side of things, as per my original point – strong financial backing is essential. Given the greater scale and increased speed of production, a stable pipeline of demand is needed to maintain the viability of offsite factories. This can be achieved in various ways.

For greater deployment of modular housing, we need more industry champions within the ranks of large contractors who can demonstrate that via these modern methods, construction giants can fast-track delivery to achieve an earlier return on investment as well as having more predictability of building programmes and profits – something they currently lack. That’s a win-win situation from my perspective.

The Build to Rent (BTR) sector is another good place to start. This is the most dynamic of sectors, and with meteoric rises in market share and demand exceeding capacity in many areas it is not only a great place to be but also a great place to invest. What is needed is a joined-up approach utilising public land supply and greater collaboration between procurement, housing providers, social and BTR landlords. This works for both investors and tenants, hence offsite manufacturers can invest safe in the knowledge that there is a guaranteed pipeline of work.

And finally, Westminster has a part to play through grants, tax breaks and subsidies aligned with offsite approaches and planning policy incentives such as fast-tracking permissions for offsite developments.

For many years the offsite community has been keen to demonstrate its capability, resilience and user comfort to provide the additional capacity and quality the construction sector needs. Many have been ‘bitten by false dawns and false promises’ in the past, where potential pipelines remained just that –potential, so they are rightly nervous about over-extending.

This is a long-term transformation of the construction sector, so a sensible but accelerated approach is needed, and the time is right to not only champion these pioneers but offer financial and planning incentives to modernise methods of construction.

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

Images:

01. The volumetric approach is still an undervalued solution to the UK’s housing and construction productivity problems.

Courtesy Premier Modular

02. Factory manufacture is providing many precision designed housing elements 2

FRAMEWORKS IN ACTION

Boho 8 – the most recent phase of Middlesbrough’s Boho Zone –is the location for the town’s digital and creative sectors and has seen modular methods transform the area.

1Previously a car park, the £2.5million project, supported by the Local Growth Fund from the Tees Valley Mayor and Combined Authority, provides additional space for companies that are rapidly expanding elsewhere on the campus, and is intended to attract new digital and creative businesses to the area. The award-winning concept by Seymour Architecture outlined high-quality facilities and a unique cantilevered design, with buildings ranging from 1,000 to 3,000sq ft. The buildings are complemented by a modern external communal space, with the aim of making it feel like a high street.

From Concept to Completion in Just Eight Weeks

CPC worked closely with Middlesbrough Council and its partner Faithful+Gould through the MB1 Modular Buildings (MB1) framework, resulting in modular specialists M-AR being appointed to deliver the project. The ambitious modular offices project began in August 2020, with construction of

the buildings being manufactured at M-AR’s site on the banks of the River Humber in East Yorkshire while the groundworks were being carried out. Just eight weeks later, four office blocks consisting of 18 individual 49m² modules had been completed and quality checked. They were erected over a five-day period.

Amanda Grimbleby, Partnerships and Business Development Director at M-AR, said: “This just demonstrates the speed in which off-site construction can accelerate the delivery of such projects, and this has all been able to happen during the Covid-19 pandemic. The innovative design created by Seymour Architecture will provide light, bright and inspiring office spaces for ambitious and creative digital businesses in the region and being part of making this happen is inspiring in itself.”

Collaboration is Key

The working relationship between Middlesbrough Council, Faithful+Gould, M-AR and CPC contributed to the success of the project. “It’s all about collaborative working and early engagement with the client and appointed company, to show what our Modular Buildings solution can achieve,” said Tony Maw, Technical Support Manager at CPC. Our relationship provided a solid foundation in understanding how each other work, helping us to work in an effective manner to achieve the best

LHC FRAMEWORK AGREEMENT FOR MODULAR BUILDINGS

quality results. I think Boho 8 is a great example what can be achieved by working side-by-side.”

Utilising Procurement Frameworks

Using frameworks for offsite projects allows relationships between clients and suppliers to develop and flourish over a longer-term period and sets out an integrated supply chain without any legal problems for procurement teams. Early engagement between suppliers and clients through the framework also ensures the risk load is shared more widely. Mark Chicken, Quantity Surveyor at Faithful+Gould, said: “CPC are very interactive, which is something you don’t get from most framework providers. This interaction gives you confidence in using their services, and you know there is always someone there to talk to for advice.”

The latest iteration of the framework, Modular Buildings (MB2), was launched in June 2021 and allows local authorities, social landlords and other public bodies to source preapproved specialist suppliers who can design, supply and install permanent, temporary, and refurbished modular buildings. The MB2 framework can be used by local authorities across the UK through LHC’s regional hubs – LHC London and South East, SPA, WPA, SWPA and CPC – and will run until May 2025.

Images:

01. Boho 8. Courtesy CPC, Middlesbrough Council, MA-R Offsite & Faithful & Gould

The LHC Framework Agreement for Modular Buildings (design, manufacture, supply and installation) is available to public sector organisations in England, Scotland and Wales and forms one of the LHC Construction, Extension and Refurbishment portfolio.

Fully OJEU compliant, the Modular Buildings Framework provides public sector organisations with easy access to offsite manufactured, volumetric and panelised building systems for the use in non-residential buildings and residential projects where they are of mixed-use development or for student accommodation for schools and universities.

For more information visit: www.lhc.gov.uk/frameworks/construction-extension-and-refurbishment/modular-buildings-mb2/

NET ZERO HOUSING LIVING WITH LOW CARBON

The Underwood is a project in Greenwich, south London, that showcases how offsite manufacture can deliver net zero carbon affordable houses for local people on time and to budget.

Demonstrating how the delivery of offsite houses does not need to be overly complicated, expensive or time consuming, this project demonstrates that with the right approach, inspiration and motivation, we can achieve net zero carbon affordable housing, using structural insulated panels (SIPs) with limited additional cost above a baseline building regulation compliant scheme and a traditional delivery method.

The client brief was clear from the outset that fuel poverty for their affordable rented tenants was a significant issue, so the houses needed to ensure that residents fuel bills stayed below £200/annum and achieving net zero carbon was a priority. The Underwood provides eight houses for affordable rent for the local community. Seven of the houses are two-bedroom (four person) and one is a fully wheelchair adapted (Building Regs M4(3)) three-bedroom (five person) house. All the houses exceed the Nationally Described Space Standards, and all the two-

bedroom homes also meet building regulation M4(2).

The team developed a concept that would create a friendly and welcoming street for the new residents with the principle of a terrace of houses with the ground floor kitchen windows overlooking the street and the living room facing the garden. The external works are shared surfaces with planting and trees to the south boundary. The project has been warmly welcomed by the existing local community and by the new residents moving in. It is an ‘ordinary’ project that countless local authorities, housing associations and developers are grappling with. But for this project, the approach to the advantages of offsite manufacture, energy and sustainability by the client and the team have made it an extraordinary project that should be seen as an exemplar of what can be achieved for local people.

The use of offsite manufacture ensured the quality required for upgrading the thermal performance of the fabric and

reducing air permeability. The timber SIPs approach provided fabulous thermal efficiency, lightweight ease of handling on a tight site and quality control. The structure has SIPs walls and roofs with enhanced insulation with concrete plank floor to the ground floor and posi-joist floors to the first floor.

The project follows the ‘be lean, be clean, be green’ principles with a fabric first approach. SIPs panels for the internal wall construction enabled the team to uprate the thermal performance of the walls and significantly reduce the air permeability of the houses. Triple glazed windows and doors complete the fabric first improvements, with clean energy created by using air source heat pumps (ASHP) for the heating and hot water and mechanical ventilation heat recovery to reduce the amount of heating required. Photovoltaic panels on the roofs provide electricity to offset the usage from the ASHPs.

NET ZERO HOUSING

By using offsite methods, the project went through planning to handover in circa 18 months, significantly reducing the traditional design programme.

All the houses delivered are social rented affordable accommodation for local residents on the housing list.

Cllr Anthony Okereke, Cabinet Member for Housing, The Royal

Borough of Greenwich, said:

“This development is an excellent

ZERO CARBON HOMES A REALITY

example of the new generation of council homes we are creating with our Greenwich Builds programme. Being net zero carbon, these homes not only fulfil our commitment to tackling the climate emergency but will also address fuel poverty for our social rented tenants by reducing electricity bills. We are delighted with how the architectural design has transformed a disused garage site into innovative and

Courtesy Fuse Architects 2

much needed council homes for local people on our housing waiting list.”

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

Images:

01-03. Using a fabric first approach and air source heat pump technology deliver massive carbon and cost savings for residents.

A first-of-its-kind partnership between a technology company and a SME housebuilder will see the delivery of highly energyefficient homes that will save consumers hundreds of pounds on household bills every year.

As part of the multi-million pound deal, Etopia Group will provide Midlands-based housebuilder Rippon Homes with its Powered by Etopia (PBE) system on several sites. This will involve Etopia Group providing pre-manufactured panels to site that will form a home’s structure – such as walls, roof and flooring. Rippon Homes, which has a 750-home pipeline, will then be able to design a property’s facade how they wish.

The proprietary technology enables homes to be incredibly airtight and energy-efficient, meaning they qualify for green mortgages, such as those offered by Barclays. These efficiencies – the homes will have at least an 88 EPC rating – will translate into huge savings on energy bills and mortgage repayments for consumers. If consumers opt to install solar panels on their homes, an EPC rating of 104 will be able to be achieved, effectively making it energy positive.

The announcement comes as annual energy bills are due to rise by up to £700 from 1 April, with Ofgem raising the price cap last month in response to soaring wholesale gas prices. The Bank of England has also raised interest rates to 0.5 percent, seeing monthly bills jump immediately for households on standard variable and tracker-rate mortgages.

Under new rules, newbuild homes constructed from 2021 are required to reduce emissions by 31 percent in preparation for the 2025 Future Homes Standard which, as set out by the Ministry for Housing, will require fossil fuel heating systems, such as gas boilers, to be replaced by low-carbon heating solutions such as air source heat pumps and solar panels.

“Helping SME housebuilders, who don’t always have the resources and capacity to innovate, has never been more critical as the UK continues to tackle the climate and housing crisis,” said Joseph Daniels, founder and CEO of Etopia Group. “We’re already seeing some of the UK’s largest lenders offer interest-rate reductions on loans if they meet social and environmental milestones, such as Lloyds’ Clean Growth Fund. In addition, with homebuyers increasingly being incentivised to purchase energy efficient properties by some mortgage lenders via cashback offers, such as those recently launched by Nationwide and NatWest, the PbE system’s green credentials have huge cost-saving implications for the end user.”

All homes can achieve an Energy Performance Certificate (EPC) rating well-above the highest category of ‘A’. In the UK, only 1% of newbuilds are ‘A’ rated, while the average rating is ‘D’. They can help contractors, developers and housing providers deliver up to 2,000 net-zero homes a year, with low-carbon technologies – such as electric vehicle charging points, air source heat pumps and solar panels available.

For more information visit: www.projectetopia.com

REALISING OFFSITE’S HUGE POTENTIAL

As offsite manufacture continues to make advances in construction thinking, Government ambitions regarding offsite are not being met, argues Guto Davies, Head of Policy at the Association for Consultancy and Engineering (ACE).

In June 2020, the Prime Minister made a speech announcing Project Speed: “We will build better and build greener, but we will also build faster.” The clarion call was loud and clear –it’s not just about ensuring our built environment is fit-for-purpose but ensuring speedy delivery too.

With pressures on financial purse strings as we come out of the pandemic, and huge political ambitions around net zero and ‘levelling up’, it is clear that major investment is only viable if it is delivered in a “better” way.

However, analysis undertaken by ourselves at ACE shows that delays are still an issue. Of the top 100

projects identified in the 2020/21 National Infrastructure & Construction Pipeline, estimates are that six months after the Pipeline’s publication, 14% were slightly delayed and 7% were significantly delayed. Only a transformation of the way our built environment is designed and delivered will address some these endemic challenges. Offsite manufacturing is central to this, of course.

Readers of Offsite Magazine will be all too aware of its potential. Not only can it help tackle the big issues, such as easing the housing crisis and helping society on its net zero journey, but it can also improve construction productivity while speeding up its delivery.

Given its huge potential, ACE was delighted to pull together the views of its members on the issue in a recently released report, ‘Project Speed and off-site manufacturing.’

Our paper outlined clear opportunities for offsite to deliver affordable housing, built-to-rent homes, elderly care, educational, custodial, defence housing, hospitals and roads. Offsite manufacture can deliver in all these areas while being more sustainable –with reduced pollution from transport around the site, as well as improved health and safety.

A Potentially Huge Prize

The experience of ACE members, backed up by research from the National Audit Office, McKinsey, and others shows that the use of offsite manufacture at scale can routinely reduce the cost and time of construction by between 30 to 50%. Applied to £11.7billion planned social infrastructure spending between 2022/3 to 2024/5, this would equate to a ‘benefit’ of around £3.5billion to £5.9billion.

Despite this, decisive action is needed to ensure offsite manufacture becomes an everyday reality for those working in our sector. There are encouraging signs from Government. It has talked of talked of a “presumption in favour of offsite”, and its report, ‘Transforming Infrastructure Procurement: Roadmap to 2030’, commits the Government to “enabling and increasing the use of ‘platform’ approaches in construction.”

More recently, the Government published its review commissioned by Lord Agnew and led by Professor Mosey with a brief to create a new ‘Gold Standard’ for public sector frameworks and framework controls. Within this, it contained a series of

proposals aimed at modern methods of construction (MMC) and promoting offsite manufacturing.”

Reality Needs to Match Ambitions

However, the ambition is still ahead of the reality in many respects. While Government has made positive noises around leveraging procurement to drive wider adoption, its previously made pledges have only resulted in the Department for Education procuring 22 major offsite contracts, with the remaining Government departments procuring only one more between them to date.

The end-result is a missed opportunity to use Government procurement to drive wider adoption. It also shows that more needs to be done to champion offsite and MMC, and that a detailed strategy is needed to enable the vision of much wider use of platform approaches and offsite manufacturing – as set out in Transforming Infrastructure Procurement: Roadmap to 2030.

We believe that a ten-year overarching offsite strategy would deliver a clear vision, ambitious objectives and goals, well-considered critical success factors, a time-bound plan with discrete milestones, and metrics to measure progress. All of which would be designed to unleash offsite’s potential far-beyond the initial 23 major projects mentioned above, and deliver consistent demand, changes in procurement, and the adoption of a more standardised component-based approach. These are all areas with potential for wider application across construction projects in the UK and beyond.

Bringing Everyone on the Journey

With much of the focus on larger projects and initiatives, we need to ensure that we bring everyone on the journey. SMEs and smaller stakeholders also have a key role to play.

Targeted support for lower-end and smaller scale adoption would also be welcome. This could include support for the manufacturers of components, rather than just focusing on larger players who gear their investments predominantly towards factories. Undertaking a capacity study for the availability of offsite options and putting forward a strategy to work with

ACE PROJECT SPEED

suppliers to incentivise gap-filling, would also be useful.

Finally, help could be given to smaller local government procurement departments to adopt offsite policies through aggregation. For example, enabling small residential urban plots across a few local authorities to be served by a group of offsite manufacturers.

Industry Needs to Show the Way

While much of our report focused on the steps Government should take, we are also aware of the vital role industry plays in this debate. We should be advocating the benefits of offsite manufacturing to all stakeholders and tackling the unfair stigma that it “restrains design”. We could encourage and embrace more collaborative delivery models with early engagement between clients, designers and offsite manufacturing contractors to explore opportunities for offsite.

Furthermore, adopting a more standardised platform approach to pre-manufactured components, would also help. Our industry has made great strides over the last decade laying the foundations for collaborative and standardised approaches through the adoption and use of digital. We can now use this to help realise the undoubted potential for offsite.

For more information and to download the report ‘Project Speed and off-site manufacturing’ visit: www.acenet.co.uk

Images:

01. Guto Davies, Head of Policy at the Association for Consultancy and Engineering (ACE)

02-03. The ACE report ‘Project Speed and off-site manufacturing’ outlines the decisive action still needed by Government and industry to make offsite manufacture an everyday reality 2 3

KEYWORKER ACCOMMODATION

THE ADAPTABLE INTERIM HOUSING SOLUTION

VOLUMETRIC™ has been working with many sectors to address accommodation needs. From safe and secure living for homeless people to onsite accommodation for keyworkers –MODULHAUS™ can be configured to meet various requirements.

With the financial effects of COVID-19 continuing to pile pressure on those most vulnerable in our communities, and the strain on our healthcare services still evident, concerning figures regarding the UK housing crisis demonstrate why the provision of quality, temporary homes remain a top priority. Designed by VOLUMETRIC™ a specialist manufacturer of rapid build solutions, MODULHAUS™ utilises modern methods of construction to achieve outstanding functional performance and energy efficiency – exceeding Future Homes Standards and delivering net zero accommodation.

Onsite Keyworker Accommodation

Despite the disruption to the economy by the pandemic between 2020 and 2021 UK housing prices increased by 8.5%. This coupled with rising rental and energy costs means that for many keyworkers owning or renting a home is extremely challenging. Recent industry analysis published in ‘The Guardian’ showed that keyworkers on the frontline of the COVID-19 pandemic would not be able to afford to buy, “the average priced home in 98% of Great Britain.”

Not only does this mean home affordability is way beyond the means of many, but research from Citizens Advice shows that fuel poverty is also

a major issue with 21% of keyworkers falling behind on their bills and one in five people considered vulnerable in arrears. One of the biggest obstacles currently facing the NHS as outlined in their long-term plan is the gap in workforce numbers as recruitment and retention decreases. Based on current trends, the total shortfall of healthcare staff by 2030 could reach 250,000. Much of this can be attributed to a lack of accommodation in areas of greatest need.

MODULHAUS™ homes offer a viable and cost-effective option for NHS estate managers. Built for adaptability with a 60-year design life, MODULHAUS™ has numerous options for configuration and fit out – making it a highly adaptable asset which can maximise the potential of unused estate space including over car parks. Stackable, interlocking units can create secure onsite keyworker accommodation.

Modular Homeless Solution housing relies heavily on costly temporary and hostel accommodation, creating a system whereby longterm housing issues remain unaddressed. Leaving many trapped in a cyclic system of permanent instability, limiting the possibility for rehabilitation, employment, and reintegration.

Adaptable, interim housing must be the answer. For those affected by homelessness, MODULHAUS™ promotes a pathway back to independence. The solution offers greater dignity whilst relieving the burden on Local Authorities and Councils of ongoing expenses associated with traditional temporary accommodation.

MODULHAUS™ is super energy efficient, costing circa £5 per week to run – meeting the guidelines outlined by the Future Homes Standard and negating fuel poverty. Addressing the need for efficiency, MODULHAUS™ homes feature low-energy lighting, as well as fixtures designed to minimise water and energy wastage. LABC Assured with a 60-year BOPAS Certified design-life, MODULHAUS™ homes are future-proofed for Building Regulation changes.

Arriving 100% complete ready for simple site connection and commissioning – design features include ergonomic internal fully fitted living space with furnishings, bedrooms, shower-rooms and kitchens complete with white goods – modules are provided on a turnkey basis, fully equipped for immediate occupation. While these benefits have already provided much-needed relief for those experiencing homelessness, MODULHAUS™ homes also have the efficiency, practicality, and adaptability to give a unique opportunity for investment in keyworker housing.

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

Images: 01-02. MODULHAUS™ homes are adaptable for a range of ownerships and locations

MODULHAUS™

THE LONG TERM, RELOCATABLE FLEXIBLE ASSET

From interim housing for the homeless to on-the-spot overnight accommodation for keyworkers – MODULHAUS™ provides award-winning, safe and secure accommodation which has been rigorously tested to ensure outstanding performance and quality.

ADAPTABLE AND SUSTAINABLE SINGLE OCCUPANCY MODULAR ACCOMMODATION

Designed to the Future Homes Standard Energy costs of less than £5 per week

BOPAS certified structure with 60-year design life

LABC Assured Building Control approval

Fully non-combustible structure

Renewable energy technology

Stackable to two storeys

Delivered 100% complete

Relocatable with over 95% material recoverability and re-use

If you have an enquiry or an immediate requirement, please contact the VOLUMETRIC™ team:

T: 01743 290 020

MAXIMISING OFFSITE INDUSTRY EXPOSURE

Following the unprecedented success of the 2021 event, the Offsite Construction Awards returns later this year and will take place at Offsite Expo 2022 – the UK’s largest offsite technology event in the construction calendar.

Taking centre stage at Offsite Expo on the evening of 20 September 2022, the Offsite Awards will be a major coming together of the industry where over 500 guests will gather to celebrate ground-breaking achievements and the pioneers who are developing radical new offsite

technologies, innovative product developments and landmark projects using factory-based methods.

Entries in to the 2021 Offsite Awards were record breaking with over 200 entries and the profile and coverage gained by all the finalists

and winners has helped to propel the sector to another level. This event is the ideal opportunity for construction professional to maximise industry exposure by demonstrating what separates them from their competitors. So, if you are proud of your exceptional team, project development or product innovation, there are just five questions to answer to grasp the opportunity to take centre stage at the 2022 Offsite Construction Awards.

Being shortlisted for the Awards will earn the recognition within the offsite community and the wider construction industry – opening doors to securing new business development opportunities.

The deadline for submissions is 27 May 2022 with the winners being announced on 20 September 2022 at Offsite Expo 2022.

Many of the sponsorship packages have already been snapped up by savvy companies wanting to take advantage of the opportunity to promote their company and maximise industry exposure.

For more information on how to get involved in the Offsite Construction Awards, please contact Rhian Morris on rhian.morris@radar-communications.co.uk

Winner of International Offsite Project - Forta Pro

WASTE REDUCTION

RECYCLE AND REUSE

Sustainable sourcing is essential at every level, and alongside energy efficiency policies and new regulations, pressure remains on the construction sector to continue to improve its building methods and product choices.

2022 sees changes to Part L of the Building Regulations come into force in June, and any new homes will have to produce 31% lower carbon emissions. This is ahead of the introduction of the Future Homes Standard in three years’ time.

PVC-U is already playing its part and for offsite construction, there are plenty of benefits to consider. Set against other potential product choices such as aluminium or timber composite, not only are there lightweight PVC-U options, making it ideal for offsite installation, but it also offers longterm durability and high performance. Plus, attractive aesthetics to support design visions, it is also cost effective and, through important initiatives such as Eurocell’s visionary and industry leading recycling processes, provides a truly sustainable product answer.

1Combined with effective glazing solutions, buildings can be better insulated and use less energy with PVC-U’s ability to offer a lower U-value for lower cost. The option to achieve excellent thermal performance results through a cost-efficient product choice without compromise, is a reason why PVC-U solutions that contain high levels of recycled content, are becoming a sustainable product choice for many.

Eurocell has been committed to recycling for over 20 years. Eurocell’s nationwide recycling service called Eurocell-Recycle meets two primary objectives: it prevents plastic window and door frame waste being sent to landfill and enables Eurocell to recycle end of life waste into new PVC-U extrusions.

Two waste plastic recycling plants at Ilkeston and Selby are at the heart of the Eurocell-Recycle service. Using a ‘closed loop’ recycling system that deals with both post-consumer and post-industrial plastic window and door frame waste, the plants are now responsible for processing over 40,000 tonnes of plastic waste per year, a figure that has been steadily rising as demand for recycled product solutions has escalated in recent years.

To further substantiate the sustainability credentials of PVC-U product solutions, the Faculty of Science and Engineering at Manchester Metropolitan University recently reviewed an array of data sets and modelling emanating from peer-reviewed publications. This has established a lifecycle assessment of the use of recycled PVC-U window frames within Eurocell’s manufacturing operations.

For example, a typical semi-detached house comprising seven windows and a pair of French doors will see an average weight of post-consumer PVC-U within the eight products plus cavity closure of 122kg. Therefore, a development constructing on average 2500 units of semi-detached houses will save around 627 tonnes of carbon dioxide equivalent per year by specifying recycled Eurocell windows and cavity closures over a competitor who is using full virgin PVC-U windows.

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

Images:

01. Two waste plastic recycling plants at Ilkeston and Selby are at the heart of the EurocellRecycle service

At the forefront of PVC-U waste recycling for more than 20 years. With our advanced closedloop recycling system, old PVC-U and off-cuts from fabrication processes are not just recycled, but turned back into brand new extruded plastic products – all at the same site. So we keep PVC-U out of landfill sites and in productive use for potentially hundreds of years.

PVC-U is a highly sustainable product, robust enough to be recycled and repurposed up to 10 times without its quality or performance deteriorating. At our recycling plants in Ilkeston and Selby, we process up to 70,000 old PVC-U window frames per week, or around 3.5 million frames per year.

TOOLS TO TACKLE THE CLIMATE CRISIS

Progress in reducing embodied carbon requires new tools and a shared language. Timber Development UK Sustainability Director, Charlie Law outlines what these should be.

The construction and built environment sector are responsible for nearly 40% of global carbon emissions, of which a significant percentage comes from the extraction, processing and energy intensive manufacturing of building products – known as embodied carbon. After many years of efforts across the industry, embodied carbon as an issue is finally emerging into the mainstream.

We see this in the debate of how we should handle our existing buildings, with the carbon cost of the proposed demolition of M&S on London’s Oxford Street grabbing national headlines, in local planning policy, with the London Plan including a requirement for whole-life carbon assessments, and in the Houses of Parliament where the ‘Part Z’ for embodied carbon recently came forward.

While excellent progress is being made, there remain outstanding challenges. For the timber industry this is seen in the debate on how to measure the impact of carbon sequestered by wood products. With the many differing opinions, it has sometimes been difficult to fully communicate the benefits which timber and timber building systems bring to reducing embodied carbon.

1In our new technical paper ‘Assessing the carbon-related impacts and benefits of timber in construction products and buildings’ we set out to solve this problem by communicating a clear process for accounting for carbon in timber buildings and Environmental Product Declarations (EPDs) in accordance with the latest European Standards (EN 15978 and EN 15804+A2) and RICS Professional Statement on Whole Life Carbon Assessment in the built environment. As with any other core part of a business, from finance to operations, ‘if you can’t measure, it you can’t improve it’. To ensure the rigorous application of these standards to an industry leading level we worked with an independent party, Jane Anderson of ConstructionLCA, a world-renowned expert on embodied carbon, lifecycle assessments and EPDs for many different materials within the construction sector, to develop this technical paper.

To fully understand the carbon impact of construction requires a whole life carbon assessment. Within this assessment it has not always been simple to quantify what the impact of the biogenic carbon, which is sequestered by timber, is on the overall carbon footprint of a construction project.

There needs to be a clear understanding of the construction product all the way from the forest –where our paper starts by looking at the forest ecosystem as a carbon sink –through to its end of life when it might be recycled into another product, converted into bioenergy, or otherwise released into the atmosphere, as well as all points in between.

Where timber is sourced from a sustainably managed forest then the sequestered biogenic carbon stored within the product can be considered as part of an assessment. On average, a balance of 568 million tonnes of CO2 has been added to the forestry carbon sink in Europe annually over the last ten years. The amount of carbon stored in harvested wood products, including timber used for building, is estimated to increase by 40 million tonnes of CO2 each year.

One of the reasons this technical paper has become possible is from the creation of Timber Development UK, formed from the merger between the Timber Trade Federation (TTF) and Timber Research and Development Association (TRADA). This paper will be the first of many as we set out to use our position in the timber industry to build a roadmap, along with the tools, training, guidance, and auditing to support the sustainable timber supply chain to become a net zero carbon industry.

You can download ‘Assessing the carbon-related impacts and benefits of timber in construction products and buildings’ for free at: www.ttf.co.uk/ download/tduk-technical-paper

Images: 01. Lifecycle assessment graphic explaining the areas of embodied carbon

MAKEOVER FOR HISTORIC PUB

De Matos Ryan architects have transformed the Grade II listed Alice Hawthorn pub and restaurant using homegrown timber and sustainable design.

Named after a famous 19th Century racehorse, The Alice Hawthorn is the village of Nun Monkton’s last remaining pub. Close, collaborative consultations with Harrogate Borough Council and the local community informed the project’s design. After several years of neglect, it was important to save the pub from extinction.

The scheme includes twelve en-suite guest bedrooms, four on the first floor of the pub and eight around a new courtyard, which extends the village green into the pub’s rear garden. The homegrown Douglas fir framed buildings use authentic agricultural building materials, such as galvanised corrugated steel roofing and larch cladding, to create the sense that the animals have only recently moved out. A simple and honest construction typology ensures that the project looks like the way it was built.

The new timber frame buildings include the sheds, field barn, stables and tack room. Double member ‘cloister’ columns engage stainless steel feet sitting on cast concrete upstands. Adjacent to the front gate, the Sheds is a single-storey infill building between existing brick outbuildings with two staff bedrooms and a bathroom. It is clad in larch with a

pan-tile roof to match the outbuildings. The Field Barn is a south facing, twostorey structure with four guestrooms. The lower level is clad in larch while the upper level is sinusoidal galvanised steel. There are no windows to the north and west to prevent overlooking and light pollution to the neighbours.

The Tack Room, a single-storey structure with a wheelchair accessible guestroom, sits adjacent to the west boundary and the Field Barn. It also provides shelter to the outdoor kitchen, pizza oven and pub garden bar. Adjacent to the east boundary, the Stables is a single-storey extension structure with three guest rooms. Both the Stables and the Tack Room are clad in larch with a sinusoidal galvanised steel roof and back wall.

Internally, in contrast to traditional pub interiors, the newbuild elements have no plaster and are lined with larch boarding and poplar plywood. Subtle distinctions between the timber species are blurred by a tinted treatment. The only internal wall decorations are lino cut prints created by village primary school children, who have a vegetable patch at the rear of the garth.

Sustainability is at the heart of the project’s design. A ground source heat pump provides heating and hot water, supplied by bore holes and supported with high levels of non-combustible mineral wool insulation and airtightness to a standard higher than current Part L2A building regulations.

The timber frame buildings are naturally ventilated through use of high-level clerestory windows and rooflights on actuators.

Solar gain is reduced by roof overhangs, which offer shading. LED and low energy lighting, as well as low volume water appliances, have been fitted throughout. The sustainable drainage system includes permeable paving and surface water attenuation tanks concealed below the pub garden. A challenge was to develop a one-hour fire resisting timber frame wall within 1m of the site boundaries. This was resolved by employing a fire resisting sheathing internally, thus avoiding carbon heavy blockwork.

For more information visit: www.dematosryan.co.uk 1 2

On completion, the newbuild scored an EPC ‘A’ rating. Biodiversity has been improved on-site through extensive planting and habitat creation. The new courtyard is bounded by borders planted with native species, which also help screen the adjacent bedrooms. An orchard at the back of the site, which would have been typical of these plots in medieval times, is being re-established with fruit trees and will ultimately supply the pub’s kitchen.

Images:

01-02. The new development has been transformed with timber into an EPC ‘A’ Rated sustainable eating experience. Courtesy Hufton + Crow

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BUILDING NEW HOMES AND MEETING CLIMATE TARGETS

AIMCH recently concluded that using sustainably sourced timber panelised methods could transform housing delivery. Stewart Dalgarno, AIMCH Project Director explains more.

The end of the UN’s climate change conference COP26 marked the beginning of the hard work required to prevent global warming rising above 1.5C. For the UK to play its part in lowering emissions, the construction sector, which accounts for 47% of the country’s total carbon emissions, must accelerate the adoption of new sustainable ways of working across the built environment sector.

Advanced Industrialised Methods for the Construction of Homes (AIMCH) is a project I believe offers the housebuilding industry a way to continue to improve the sector’s environmental performance.

The challenges faced by AIMCH are not insurmountable, but we must acknowledge that it is concluding at a time when demand for high quality, energy efficient and affordable housing continues to grow. What excites me most about it though, is that the project could offer solutions to

skills shortages, the ageing workforce and poor productivity – challenges not limited to the housing sector, while also responding to requirements to use sustainable materials and panelised offsite systems.

AIMCH's ambition is to use industrialisation to transform how we build our homes in the UK, leading to more homes that can be built quickly, viable and sustainably. If we get it right, I believe the AIMCH project will accelerate the delivery of the 120,000 new homes the UK needs each year, for an acceptable cost, compared to masonry-built homes and with at least 30% reduction in build times.

An integral part of the project has been the completion of a whole life carbon assessment of current building regulations over a 60-year design life, assessing four typical homes across masonry, open and closed panel timber methods. The report’s findings indicate five tonnes of embodied

carbon saving, per four-bedroom home, when using timber construction compared to masonry, equivalent to 16,500 road mile emissions. The report also finds that aerated masonry blocks have half a tonne less carbon emissions at end of life than timber frame construction methods. The carbon sequestration benefits of timber have been used in the research, benefiting all construction methods, where elements of the build use timber, such as internal non load bearing walls, floors and roofs.

Many of our partners are working on exciting developments, using proven, reliable and viable panelised timber based offsite systems, which will soon transform how the housebuilding sector operates. As part of AIMCH, Barratt Developments PLC has created a Z House – a zero carbon concept house that applied 50 different solutions to understand how we will deliver the ‘sustainable home of the future’. It is located on the University of Salford’s campus with their scientists tasked with measuring its energy efficiency to provide hard data on the home's design versus actual performance.

The home’s clever design feature’s high performing energy efficient building fabric, using Barratt Developments’ internal timber framer Oregon’s advanced panelised timber systems at its core. The home incorporates PV solar panels and battery storage to generate and store power, electric car charging points and an air source heat pump that transfers heat from the outside to water for home heating and hot water use. Inside, underfloor heating, innovative infrared panels and skirting heating systems provide instant zero carbon heat, a fridge controls humidity levels to reduce food wastage by 60% and atomising showers that could cut water usage by 80%.

As research continues into sustainable housebuilding, developers and housebuilders can use AIMCH findings as a starter for assessing how they can lower embodied carbon emissions of materials used in construction and their impact on lower whole life carbon emissions. Such is the environmental benefits of building houses with timber components or build methods, the UK Climate Change Committee reports that the UK can triple the amount of carbon captured in homes by building 270,000 timber frame homes each year.

Where houses are built is changing too. Increasingly more homes today are manufactured offsite and assembled at the development. New

offsite factories developed by AIMCH, are being designed to include PV electric power generation to run machinery, electric forklift fleets and EV car charging for employees, such that they produce more power than they use, with any surplus recycled back into the national grid, making the transition to net zero carbon manufacturing a supply chain reality.

In the long term, battery storage systems could be used in these factories to store power 24/7 for continuous manufacturing needs. In addition, zero factory waste goes to landfill and 100% of waste is either repurposed, reused or converted to energy through large-scale waste to energy plants.

PANELISED TIMBER A CARBON CUTTER

3

The UK needs more homes. At the same time, we must play our part in limiting the dangerous impacts of the climate crisis and transition to net zero carbon homes and businesses.

Continuing with the status quo in the housing sector will likely see the UK fail on both fronts. However, I am confident that projects like AIMCH will catalyse industry to accelerate near to market, reliable, viable and sustainable offsite solutions that transform how homes are built. Additionally, this will increase housing output, while helping the UK meet its environmental obligations to limit climate change to 1.5C.

Images:

01. Stewart Dalgarno, Project Director, AIMCH 02-03. Timber systems offer many low carbon, energy efficient housebuilding options

The report ‘Whole Life Carbon Assessment of Homes’ by AIMCH concludes that using sustainably sourced timber panelised offsite methods to build new homes rather than masonry products can reduce the carbon impact of construction.

On a whole life carbon basis, the study predicts that up to 5 tCO2e per 4 bed dwelling, equivalent to 16,500 road miles, could be saved, when using timber panelised MMC methods.

Using the RICS Standard for Whole Life Carbon Assessment, the report represents a rigorous cradle-to-grave assessment of the carbon impact of both types of construction materials and their respective methodologies. 82% of emissions are generated from the homes operational use over 60 years, which is the same for both methods. 14% of emissions are generated from the materials and construction process. A small proportion of emissions are generated at end of life.

The study, authored by green energy consultancy Verco, examined four types of home utilising either: masonry – aerated blockwork and offsite manufactured open and closed panel timber MMC, both with brick cladding. Carbon sequestration benefits of timber, in line with RICS protocols, were applied to all methods of construction, for example benefiting masonry homes bult with timber floors and roofs. End of life assumptions used identical 90% recycle/re-use and 10% to landfill ratio across both material types.

Cementitious products including roof tiles, concrete blocks, brick cladding, strip foundations and floor slabs, were found generally to have the highest lifecycle embodied emissions. Conversely, timber frame wall elements sent to landfill, were found to produce 0.5 tCO2e emissions at end of life, compared to aerated concrete blocks.

Panelised timber construction methods outperformed masonry construction on a whole life carbon basis, when comparing the direct substitution of various wall elements – external, load bearing and party wall elements. Embodied emissions of these wall elements being as much as 82% less than that of the masonry construction. In addition, timber offsite key properties contributed to reduced emissions.

For more information and a detailed summary of AIMCH’s report Whole Life Carbon Assessment of Homes visit: www.aimch.co.uk

BRINGING ACCURACY TO OFFSITE

Offsite construction provides many benefits and at its core is the need for accuracy. Nick Milestone, Operations Director at Sigmat explains why Building Information Modelling (BIM) is a perfect partner for factory-based design.

The clash detection capabilities, enhanced level of detail and greater visualisation that the 3D digital environment offers, all provides the assurance that if it fits in the model then you know it will fit on-site. While this assurance is of course valuable on any construction project, it’s perhaps especially critical when it comes to offsite – given that one of its primary advantages is for on-site assembly to be both quick and efficient.

If components don’t fit together correctly, then that level of efficiency will fall dramatically. Essentially, it’s

the idea of a digital rehearsal. You get to construct it twice: once in the digital environment and once on-site. From accuracy at the detailing phase through to on-site coordination, Tekla software comes into play at every stage and feeds into our Virtual Design and Construction (VDC) processes.

Taking this theme of accuracy further, Sigmat recently worked closely with Trimble to embed Sig-Deck (own decking profile product) into the Tekla BIM library in Tekla Structural Designer. Having access to this product-specific content will in turn lead to enhanced

levels of accuracy, as well as aiding engineers from a design calculation point of view.

Another benefit of BIM for offsite is the data integration that it enables. All the constructible data is present and co-ordinated throughout the entire process, ensuring that the high levels of accuracy are maintained from the detailing stage through to factory fabrication and beyond.

When it comes to fabrication, we’re able to upload the CNC files from the Tekla Structures model directly

Our OJEU-compliant framework agreements provide public sector organisations with easy access to procure works, products and services for the construction, refurbishment and maintenance of social housing, schools and public buildings.

LHC strives for excellence in the services provided to their clients and aims to deliver the best solution to suit every project’s individual needs.

Our dedicated Client Support and Project Support teams are on-hand to assist throughout the life of the project.

For more information on how our frameworks can work for you, get in touch.

STEEL

into the factory and use this data to programme our machinery. When processing stud and track profiles, for example, the machines will use the model data to correctly profile it, cut it to specification, drill the holes, etc. Fully automated, this enables our steel frame fabrications to be carried out to extremely high levels of accuracy – to within 2mm.

As well as offering a connected data journey, the Tekla modelling software is also designed to work with a variety of construction materials, including steel, concrete and timber.

At Sigmat, we work with both hotrolled and cold-formed steel. As such, it’s important that our chosen modelling software can keep up and allows us to detail and consider all materials within the one model environment. As well as saving time and improving productivity levels when it comes to the detailing process – avoiding the need to swap between multiple software interfaces or deal with several file types – this is another

factor that contributes to high levels of accuracy.

Sustainability is a key consideration for us all. Thanks to our BIM workflows and the accuracy that this 3D modelling enables, it means that we can achieve zero waste. With correct material quantities ordered, thanks to the automatic quantity take-offs – no rework required due to detailing or fabrication errors and integrated data.

In addition to the Tekla structural modelling software, we have recently incorporated Trimble Connect –Trimble’s cloud-based collaboration platform – into its business. Used throughout the company, both internally and externally, Trimble Connect is facilitating effective communication and coordination.

As well as using the Trimble Connect platform to share files and models internally within Sigmat project teams, we’re also able to better communicate with the client and other key project stakeholders. Everyone is a part of

For more information visit: www.tekla.com/uk 3 2

the same project. While collaboration is important on any construction project, it’s perhaps especially critical when it comes to offsite, volumetric and modular. For example, our pre-panelised frames will often require close co-ordination with M&E contractors, ensuring that we are all aware of what the other party is doing.

At the moment, we’re working towards BIM Level 2+ and ISO19650. A key part of this is working with our clients within a federated environment. With the one-model approach, we stand to achieve greater levels of clash detection, a seamless design process and improved collaboration and coordination. It’s clear that BIM has been a really big part of offsite, developing alongside the sector as it has grown in popularity and strength. The changes seen within construction, offsite and BIM technology in the last 25 years has been extraordinary and the next 25 years promises to be just as instrumental.

Personally, as we move forwards, I can see the industry shifting towards a more iterative, predictive and intelligent form of modelling, using data from past projects and designs to inform and influence the new. Also, an emphasis on standardised platform design. Currently, we engineer and design every building and structure on an individual, one-off basis, rather than using a standardised platform as a base. Doing so could help to boost Offsite’s efficiency and productivity benefits even further.

Images: 01-04. Modelling software creates a connected data journey and is designed to work with a variety of construction materials, including steel, concrete and timber

MOVING HEALTHCARE WHERE NEEDED

The design team that developed the temporary NHS Nightingale Emergency Hospitals at the height of the COVID-19 pandemic in April 2020, oversaw the completion of the first of 40 community NHS diagnostic centres opening in England.

To reduce the current pressures on the NHS, interdisciplinary design consultancy, BDP and its construction and facilities management partner, CFES have been working with University Hospitals Dorset NHS Foundation Trust to open a new centre for breast screening and diagnostics in Beales department store in Poole. Situated in the Dolphin shopping centre, it will also offer testing and assessments for orthopaedics, ophthalmology and dermatology diagnoses.

In a highly sustainable and efficient move, the BDP team has reclaimed and reused materials from the demounted Nightingale Hospitals across the UK to build a one-stop-shop for much needed and overdue checks, scans and tests in the community.

Paul Johnson, Architect Director at BDP, who also led the design of the Nightingale Hospital in London’s ExCel centre, explains: “This project is the first of its kind in the country. Not only does it support a circular economy by reusing the materials from the

emergency COVID-19 hospitals in an existing building, it is also built on the same collaborative and sustainable methods of design and construction.

“NHS waiting lists are at an all-time high and through good design, based on imaginative adaptation of space and recycling of equipment, we are creating real solutions to the problem. As a collaborative, interdisciplinary team, we are thinking bigger about the issues faced by today’s society. This new centre will help bring true health benefits to the community,

DEMOUNTABLE BUILDINGS

reduce pressure on our NHS and give a welcome boost to the retail sector. We are very proud to be a part of such an impactful and important initiative and hope to deliver this flexible and repeatable solution for another 39 diagnostic centres in original, underutilised spaces across the country.”

The new centres will benefit millions of people by providing earlier diagnostics and more convenient and accessible treatment in communities across the country. The design also contributes to the NHS’s net zero ambitions by providing multiple tests at one visit, reducing the number of patient journeys and helping to cut carbon emissions and air pollution.

Ashleigh Boreham, Deputy Director of Design and Transformation at Dorset Clinical Commissioning Group, said: “The pandemic has affected the way NHS trusts deliver services. Unfortunately, this meant many outpatients appointments had to be cancelled to reduce the spread of infection with the rise in number of patients with COVID-19. We have reached a critical point where we have to manage the backlog and protect the NHS, which has led us to the opening of this centre. I’m so pleased at the

speed we have mobilised this solution but not at all surprised.

“This team deserves a lot of credit. Adapting and repurposing unused retail space is going on elsewhere in the country but to work within this existing centre and create something built simply for the outpatients, for diagnostics and assessment, is quite different – it’s a first.”

Rob Doubtfire, Managing Director at CFES, added: “Working within established relationships in proactive design and build project delivery has delivered real benefits for the NHS for the first of this kind of Community Diagnostic Centre. The use and re-use of materials from Nightingale stock

requires quick and close engagement from all partners and once again we are pleased to have been a part of this with the NHS and BDP.” The community diagnostic village in Poole is now open for patients referred for assessments from local GPs.

For more information visit: www.bdp.com

Images:

01. Dorset Health Village diagnostic design instruction manual showing circular offsite thinking. Courtesy BDP 02-03. The use of efficient demountable healthcare buildings could only have been achieved with offsite manufacture. Courtesy University Hospitals Dorset NHS Foundation Trust. 2 3

WORKING AT CHANGE

There is a real need for skilled workers in both the construction and manufacturing sectors, but as Ron Clarke, CEO of the McAvoy Group argues, offsite manufacturing may provide many answers.

A recent report issued by the Construction Industry Training Board (CITB) and Experian that covers the period 2021-2025 highlighted the need for an extra 217,000 workers in the construction sector. This equates to 43,000 workers per year over the next five years.

Furthermore, in his 2016 Review of the UK Construction Labour model, Mark Farmer identified the real ticking time bomb as being that of the industry’s workforce, size and demographic. It was noted at the time that, based purely on the existing workforce age and current levels of new entrant attraction, there could be a 20-25% decline in the available labour force within a decade.

Additionally, referring to the 2015 Arcadis paper ‘People and Money’, Mark Farmer highlighted the need to recruit 700,000 people in the construction sector to replace both those retiring and those lost through natural leakage to other industries. It is clear then that the demand for extra workers will not be met through new industry entrants. Hence, it should be considered – how do we attract more people to the industry to address this deficit? I would argue that offsite manufacturing (OSM) can be part of the solution.

Other industries may not experience the same growth trajectory as construction – therefore, this presents a clear opportunity to attract people into the construction sector. OSM is ideally placed to attract people, given its emphasis on creating buildings in a factory setting. For instance, the transition from one manufacturing industry to another, such as modular construction, is likely to be less challenging for workers than if they were to transfer from a manufacturing environment to a construction site environment.

OSM also offers a much more attractive work environment than the traditional construction setting, where all works are carried out on-site and factors such as weather conditions make it considerably more difficult to deliver projects with time and cost certainty. Shift patterns can also be introduced much more easily in a factory environment, which can allow flexible response to demand. A manufacturing-led approach leads to a less itinerant workforce too, as the focus is on one location. Breaking down the manufacturing process into component parts also alleviates need for wide skillsets and training can be given more easily to upskill the labour force. All this means that OSM is much less exposed to high labour costs, particularly in periods of high demand.

It is a well-rehearsed fact that productivity in the construction sector is extremely poor when assessed against other industries. Manufacturing-led industries tend to perform much better when automation and technology play a significant part in productivity improvement. During periods of high demand for labour, productivity tends to reduce due to less productive workers entering the industry which negatively impacts overall productivity. This is due to labour being the dominant determinant of overall unit productivity. In other industries, where automation is more prevalent, productivity is more uniform. A manufacturing environment proves less susceptible to productivity volatility.

With its appeal to a wider spectrum of workforce, OSM has a huge opportunity to develop and reduce the overall demand and reliance on a decreasing trade-based skills pool. Workers can be trained to the appropriate skill level needed, providing a much greater pool to recruit from. OSM is also better placed to invest in apprenticeships via structured training schemes. Apprentices will be employed at the same location throughout their apprenticeship, which provides a stable learning platform for new recruits. With a consistent flow of work through the factory, offsite can and will play a major part in addressing current and future skills shortages.

For more information visit: www.mcavoygroup.com

Images:

DECARBONISING PROJECT DESIGN

As a core material to construction, concrete is under pressure to provide details on its sustainability credentials and accelerate the drive to net zero carbon.

As an aid to this aim, Britain’s concrete producers have joined forces in one association to represent the industry and accelerate its journey to beyond net zero carbon emissions. British Precast, whose members include manufacturers of concrete masonry, paving slabs, structural sections and drainage systems, has merged with the Mineral Products Association (MPA) which represents all the UK’s cement makers, over 90% of aggregates producers and more than 70% of ready-mixed concrete suppliers.

The merger gives the British concrete industry a single voice, with the sector’s advocacy vehicle – UK Concrete – driving forward a common agenda to set the record straight about concrete’s role in sustainable construction and address the challenges of climate change. The UK concrete and cement industry has already reduced absolute carbon

emissions by 53% since 1990 and the merger will unite the sector behind its ambitious ‘Roadmap to Beyond Net Zero’ by 2050.

“This is a landmark moment in the evolution of the UK concrete industry which is already a global leader in terms of decarbonisation, recycling and biodiversity enhancement,” said Nigel Jackson CEO of the MPA. “Now more than ever the concrete industry must work hand-in-glove to promote the essential role this amazing and under-appreciated material plays in our economy and our quality of life. Mitigating the industry’s environmental impacts whilst delivering solutions that help people to adapt to climate change is an important balance to be struck. With the entire sector united and pulling in the same direction we are better able to achieve our shared goals.”

Alan Smith, who retires as President of British Precast, adds: “British Precast has been affiliated with the MPA for the past decade and the successful relationship we have built has given our members the confidence to fully support this merger. Coming together enables the industry to operate more strategically, rejuvenating our determination to rise to the challenges of climate change and emphasise the importance of our industry in climate adaptation.” A result of the merger, two new MPA product groups have been formed – MPA Precast and MPA Masonry.

Carbon Calculations

Measuring carbon is a complex process and lack of reliable data is a constant source of frustration for many construction and sustainability professionals. Laing O’Rourke has developed a new, industry leading

carbon calculator which can quickly analyse levels of embodied carbon using the digital model, enabling its technical team to reduce the carbon content of projects.

The digital tool which has been developed in line with latest industry guidance focuses on the embodied carbon content of the sub- and superstructure elements, which can account for more than half of the upfront embodied carbon in a typical building project.

Since May 2021, Laing O’Rourke’s inhouse technical leaders have used the new calculator on 14 bid submissions, quickly identifying changes that reduced the embodied carbon in the original designs by up to 19%. Phase one of the carbon calculator uses an internal Laing O’Rourke app, which automates the analysis of the digital model. It extracts and indexes key information relating to a project design, such as component quantities and classification information.

“The app creates an auditable trail of all model revisions through the design phase,” says Joanna Vezey, Europe Technical Director at Laing O’Rourke. “This brings benefits not only to carbon measurement, but also change, data validation and cost control. It does this by processing thousands of models each day across both of our operating hubs, constantly checking

for new models and changes to existing ones. It currently holds several billion data points.”

In phase two of the process, the app connects to a second database which houses all of Laing O’Rourke’s carbon material data. The company’s material database has been developed using information provided from the Inventory of Carbon and Energy (ICE) database and continues to grow as the business adds Environmental Product Declaration (EPD) data from its supply chain partners.

“The final data is automatically recorded within the database and fed into a user-friendly dashboard, which we can use to assess the embodied carbon in the baseline design,” adds. “It displays the data in real time and presents a carbon heat map of a project – which clearly identifies the embodied carbon of each component and where the greatest reductions can be achieved. This has allowed our teams to present alternative options to clients to reduce embodied carbon.” The detailed analysis is building on the benefits of Laing O’Rourke’s offsite manufacturing capability and operating model.

“Our new carbon calculator cleverly merges data from different systems, analysing carbon content across a project and optimising our DfMAled delivery,” adds Rossella Nicolin,

Structures Technical Director at Laing O’Rourke. “These learnings are now better understood and will help our Technology and Innovation team continue to make progress. The construction sector faces a major challenge in finding ways to reduce scope 3 emissions. This breakthrough tool helps us start to make progress. We are looking to broaden the tool’s application to help us decarbonise other standard components of builds and apply it to facades as well as structural works.”

Demand for environmentally efficient technologies is evolving quickly with efforts to reduce carbon emissions being rapidly accelerated through continued product innovation and new building regulations. To date the results have been impressive and have enabled Laing O’Rourke project teams to develop carbon reduction strategies with clients, designers and supply chain partners.

For more information visit:

www.mineralproducts.org

www.laingorourke.com

Images:

01. UCL New Student Centre London. Courtesy Cornish Concrete Products Ltd

02. Laing

PROMOTING TRIED AND TRUSTED

Lee Jones, Head of Manufacturing Solutions at NBS outlines why marketing in the era of the ‘Code for Construction Product Information’

may be

unlike any other era for construction information and benefit both manufacturers and specifiers alike.

Construction product marketers will, for the first time, be given the chance to incorporate the Code for Construction Product Information (CCPI) into their planning. Research from NBS’ Construction Manufacturers Marketing Report, reports that four out of ten marketers expect the Construction Product Association (CPA) code to have a positive influence on their marketing.

Dame Judith Hackitt’s damning report into building safety failures, ‘Building a Safer Future’ identified the need for a radical rethink of the building regulatory system, particularly in the testing, information and marketing of building products. The industry reacted and the CCPI outlined a new approach. Consisting of eleven clauses, it covers critical aspects from responsibility for product information

to transparency of information regarding performance and proof of stated claims and competency.

Developed by the CPA following industry-wide consultation, this code aims for product information to be clear, accurate, up-to-date, accessible and unambiguous. Whilst some people may be apprehensive, this system will in fact prove beneficial to manufacturers, specifiers and end users– raising safety standards, meeting regulatory compliance and increasing sales potential.

Prioritising Product Information

In-line with changes to building safety legislation, the CCPI aims to make supplying product information in a digital format, a baseline requirement. Yet research has shown that proper

management of this data is still under the radar for many. Worrying still, is that according to NBS and Glenigan’s Construction Manufacturers’ Marketing Report, only one in three construction product marketers know it’s a problem.

Instead, many are still turning to PDFs as a way of providing product information – 63% in fact. Yet this is a hazardous and shortsighted approach. PDFs cannot be easily replaced, running the risk of redundant information making its way into records and leading to incorrect installation or maintenance Product information management (PIM) systems as well as product libraries and databases are a much more effective method, integrating into manufacturer websites and autoupdating the product listing.

CONSTRUCTION PRODUCT INFORMATION

The move to digital will support the sales cycle. Research has shown that supplying information digitally is now integral to the way specifiers and architects work. In NBS’ Digital Construction Report, it found that 81% of specifiers wanted manufacturers to provide information as BIM or digital objects – with medium and larger practices particularly wanting information in this way.

Specifiers are now also increasingly using product specification platforms where digitally supplied product data is crucial to their working practices. Detailed product, performance and fire certification information can be found at the click of a button, be it a product, material, or system required on their project.

The CCPI is about fundamentally improving safety. Having product information in a digital format is also beneficial for manufacturers – allowing them full oversight of where it’s being used. This quality control measure will ensure that only the most up-to-date information is being used, raising overall safety standards.

The sector is changing quickly but these recent updates have the safety of occupants at the heart of their design. Whilst currently, the CCPI will apply to the UK market only and is a voluntary code, this when coupled with the further building safety regulation is likely a sign of things to come in other markets. Those looking to get ahead should welcome the changes with open arms, bringing them up to speed with future compliance and regulations and opening the door for further sales potential.

For more information and to download Construction Manufacturers Marketing Report visit: www.reports.thenbs.com/ construction-manufacturersmarketing-report-2022/

Images:

01. Lee Jones, Head of Manufacturing Solutions, NBS

02. The latest NBS report provides information on the changing construction marketing landscape and the importance of providing the correct and current messaging across all product marketing channels

CCPI & VERIFICATION

03. CCPI compliant products will create a safer built environment 2

The CCPI was created to promote an urgent and positive culture and behaviour change in the way the construction product manufacturing industry manages and provides information on their products. The CCPI was initiated by the CPA as a direct response to Dame Judith Hackitt’s review of Building Regulations and Fire Safety set up in the wake of the Grenfell Tower tragedy.

The CCPI will help organisations drive higher standards in the presentation of construction product information, prioritising building safety. The CCPI seeks to provide assurance that any information about products, whether written in a brochure, a presentation, or on a website or social media, the CCPI will seek to provide assurance that users of product information have the necessary facts when making decisions about specifying or installing their verified products.

The Code for Construction Product Information verification process consists of a product safety-related leadership and culture survey, assurance of organisations product information management systems, and validation of specific product set evidence submitted to demonstrate conformance with the eleven clauses that make up the CCPI, ensuring accuracy in the creation, communication and management of ‘Construction Product Information’. The CCPI has an essential role to play in helping to facilitate culture change and drive development and learnings around a collaborative community of those committed to providing trustworthy and reliable product information.

There are eleven Clauses of the CCPI which cover a wide range of matters from responsibility for product information, to accuracy of and clarity of performance claims made, general information and competency. The CCPI is built around five ‘acid tests’ - product information must be Clear, Accurate, Up-to-date, Accessible and Unambiguous.

The aim is that clients, specifiers and users will insist on only working with CCPI compliant products. As the Building Safety Regulator and National Regulator for Construction Products (NRCP) get established, CCPI is an effective way to help the industry demonstrate it is up to the challenge and responding to the issues being raised.

For more information visit: www.cpicode.org.uk

ARCHITECTURAL AND AESTHETIC

Lewisham Exchange is a triumph for offsite construction and Mechslip technology and highlights the many strengths that brick slip systems offer design teams.

The construction site has changed dramatically over the years, with safety, sustainability, efficiency, and legislation all driving factors that have led to product innovation and materials used, affecting how construction methods are approached. But now, developers and contractors are looking at other means to make gains. Most notably, the construction process and method itself. As such, offsite construction has increased in popularity thanks to its various benefits from a cost, time and waste saving perspective, and efficiency of construction, storage, and labour.

One project that has benefited from this increasingly popular process is the Lewisham Exchange development. Primarily, offsite construction for this project was chosen due to the time saving properties and cost benefits provided. However, the development did not concede on design or

aesthetics, instead, improving on these key aspects contrary to what might be expected from a modular constructed, offsite build.

The Lewisham Exchange development stands more than 100m in height at its highest peak, making it the tallest modular student accommodation building in Europe. It is built from 3D volumetric structural modules, which were completed offsite by specialists Vision Modular, and is one of only a small number of U.K construction projects to utilise this method. The twin-tower block structure consists of 35 and 20 storeys and accommodate more than 750 student apartments and around 70 affordable homes. Meanwhile, its commercial properties at the foot of the structure achieved an ‘Excellent’ BREEAM rating, putting them in the top 10% of buildings from a performance perspective.

The Lewisham Exchange project was constructed by Tide Construction using 3D volumetric structural modules, manufactured offsite. This enabled on-site construction to be streamlined and contributed to the impressive 35-week completion of the brick slip cladding installation by Century Facades Ltd, who also carried out the window installation offsite.

The modular build saw the housing ‘pods’ manufactured in optimal factory conditions, including windows, which were then delivered to site where they were erected around the building’s lift cores. Then, once ten or so stories were complete, the external envelope’s Mechslip cladding was constructed in unison, chasing the finished pods up the building.

Offsite construction of the building’s modular pods not only ensured time

saving benefits compared to more traditional methods of concrete or steel frame, but also quality of product with each one being manufactured in optimal facility conditions for consistency of quality. Furthermore, sustainability efforts were achieved through the reduction in transportation movements to and from site meaning less trucks needing to complete journeys for the finalised modular pods.

Mechslip

Mechslip was chosen primarily for two key reasons, its exceptional A1 rated fire accreditation and innovative natural brick cladding aesthetics. These benefits overcome difficulties with competitor products that in the past have either not been fire accredited or from an aesthetics perspective, look unnatural with clay extrusions which can’t compete with Ibstock’s eye-catching, real cut bricks. Importantly, the development also breaks the narrative surrounding modular structure builds and their limited design availabilities that come with the technique. As, although the modular construction method was used, Lewisham Exchange showcases incredible architectural and aesthetically pleasing detail thanks to the Mechslip cladding technology.

The Mechslip technology utilised on the Lewisham Exchange project was produced jointly by Ibstock the UK’s leading brick manufacturer and building envelope specialist Ash and Lacy, with distributor RGB Facades supplying materials to installer Century Facades.

Mechslip boosted the construction and architectural aspects of the build due to its ease of installation and flexibility in design, useful when working with modular construction. Such is the ease of installation, the cladding took just four months to cover the 100m high, 35 and 20-storey buildings. It’s this speed and practicality alongside the product’s diverse design offering that highlights its popularity as first choice for innovative, modern-looking developments.

Lewisham Exchange was the most advanced Mechslip application to date, with more than 10,000sq m of the technology contributing beautiful, intricate, and complex arches, soft returns, and bond patterns across the

BRICK SLIP SYSTEMS

structure. The arches themselves were constructed on-site, allowing for full creativity of design, and not being limited in size or shape for transporting purposes that other projects may fall foul of.

Brick returns leading into windows, eye-catching vertical coursing and large curved soffits all added to the modern architecture of the Lewisham Exchange to form an overall striking façade and geometry in the centre of urban London to really capture the vision of JTP Studios, the architects for the project in intricate detail. All of which were sourced from a range of more than 300 brick options, in both shallow and deep form, and allow for unique design iterations suitable for varying project needs. While the technology also boasts a lighter overall weight compared to traditional masonry and comes with the reassurance of an A1 fire safety rating and BBA accreditation and other quality identifying weather and performance standards.

The Lewisham Exchange development is an example of how innovative technologies such as Mechslip can combine with the increasingly popular offsite construction processes to make real-world gains on sustainability, time, and cost efforts across a modern newbuild – all without compromising on aesthetics and quality. Partnering with companies such as Ibstock and Ash and Lacy who develop these innovative technologies, understand the move to more modern construction approaches, and proactively facilitate the uptake of them through product innovation, ensures your next project can be a success for future generations.

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

Images: 01-04. Lewisham Exchange saw the most advanced Mechslip application to date

MODERN METHODS OF RECRUITMENT

Venatu Recruitment Group are leading the charge to transform the offsite recruitment landscape. James Shepherd, Divisional Manager, shares his insights into the challenges for 2022.

With six UK locations, and plans to develop further throughout 2022, our MMC team are ideally placed to service key players within the industry. Supporting the growth of many recognised industry leaders, we have become specialists with an in-depth knowledge of the offsite and modern methods of construction (MMC) sectors.

I have an overwhelming enthusiasm for the offsite market and have a few observations about this growing sector.

As an industry the offsite sector is creating jobs and environmentally friendly, sustainable solutions to enhance the UK construction economy, with the modular housing sector alone

growing by 6% in 2021. Long gone are the days, and opinions, that modular build is less robust that traditional build methods and we now see some very high quality and energy efficient projects making their way to market.

Having worked in the construction and offsite sectors for most of my career, I have experienced the growth in demand for both temporary and permanent staffing as the sector expands. Bringing with it several challenges, particularly in an industry that was already facing skills shortages – which have only worsened following the recent pandemic.

With the sector’s ongoing growth we need to attract new talent, but prospective employers need to keep

an open mind and embrace flexible thinking during their recruitment processes to enable them to consider other industries, including manufacturing, engineering and construction, where skillsets can be transferable.

In addition to the traditional commercial and production-based roles, we are seeing the growth of recruitment in areas that include logistics, digital marketing and technology driven roles. However, the biggest increase, and a priority growth area for Venatu, is the provision of temporary production staff.

We have doubled the number of consultants we have focusing in this area, as well as within our backoffice support and payroll functions. The recruitment of temporary staff to support several of our clients has allowed us to contribute to their ongoing growth. By enabling the opening of additional offsite manufacturing factories and increasing staffing levels to operate second shifts, we have contributed to the increase of productivity and output within the sector.

With the recent appointment of three industry leaders to the £600million framework, set up by the National Housing Federation, the recruitment and skills shortage looks set to continue.

If you need any support with the growth of your existing workforce, me and my team are ready to assist with all your recruitment needs.

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

Images: 01-02. Venatu Recruitment Group are a supplier of permanent and temporary staffing solutions based in South Yorkshire.

LSFA LAUNCH LIGHT STEEL TECHNOLOGY VALIDATION GUIDE

Developed by the Light Steel Frame Association (LSFA) – the Technology Validation Guide outlines accreditations that certify system performance, robust testing protocols and informative guidelines to support those manufacturing and specifying light steel framing (LSF) systems.

As a proven and well-established offsite manufactured technology, light steel frame is trusted and widely used throughout the UK across all construction sectors however, this document covers residential and commercial bedspace only.

Open-Source

Freely available to download from the LSFA’s website, the Technology Validation Guide covers light steel frame infill and oversail together with panelised and volumetric modular systems. The accreditation pathway is determined by the type of system, the construction sector and design parameters of the structure. Testing is required for the structural elements

along with building physics data for fire, thermal, acoustic, and structural performance, for example. The types of testing along with the organisations who can carry out this work are highlighted in the document along with the relevant test standards.

Driving Collaboration and Growth in the Light Steel Framing Sector

Established to influence legislation, regulation and to support the overall objectives and growth of the sector, the Light Steel Frame Association is raising awareness of the cost, performance and productivity benefits and supporting the specification of light steel framing systems.

The Validation Guide provides a concise high-level overview which signposts construction professionals to valuable and trusted sources where further information is available.

For more information on the LSFA and to download the Light Steel Frame Technology Validation Guide, go to: www.lsf-association.co.uk

NEW APPROACHES TO FOUNDATIONS FOR MODULAR CONSTRUCTION

With increasing demand to build on Brownfield sites, piled foundations are on the rise – but with a difference.

Due to the need for piled foundations, Brownfield sites often reduce project viability as builders often default to pile and beam foundations however, this approach is rarely cost-effective or time-efficient for modular builders. The primary downfalls of this approach are the time, cost and environmental impact of excavating for and constructing the beams. A huge amount of spoil goes to landfill, and a large amount of concrete is used, at great cost to the builder and the environment. These processes also add unnecessary time to the programme.

Luckily, the geotechnical engineers at Abbey Pynford have developed a solution. They have rationalised the foundation process, doing away with beams, and designed a new capped mono-pile foundation system, using

their own Eco concrete mix, called Quickcaps. A capped mono-pile system offers all the advantages of traditional piled systems allowing you to overcome an array of ground issues and planning constraints without the bulky design and subsequent costs.

Unique to Abbey Pynford, the cap is poured while the pile is still wet, saving days off the programme. When compared to a pile and beam scheme, Abbey Pynford claims to be up to 75% faster and save their clients an estimated 50% on their foundation costs. Quickcaps are the most sustainable foundation choice when a piled solution is required, answering the industry demands to reduce construction's environmental impact.

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

Images: 01-02. The new foundation process does away with beams and uses a capped mono-pile foundation called Quickcaps 1 2

MAXIMISING THE MODULAR MARKET

2021 was a pivotal year for Modular Group Investments Limited (MGI) that saw it become one of the fastest-growing players in modular construction, having acquired three businesses already. CEO Nick Cowley looks back over the year’s developments.

MGI was started by Michael Garratt – a young, passionate property developer who could see the enormous potential of modular construction. His aim was to bring together suppliers who serve the modular sector under the MGI umbrella, eventually offering everything a modular builder needs, exactly when they need it. To make that vision a reality, Michael was on the lookout for outstanding businesses with a track-record of success serving the modular market – or at least skills that would easily translate into modular.

It was that search that first led him to Euramax Solutions. I joined the business as Managing Director in 2019. Euramax Solutions Limited is a 70-year-old window and door manufacturer making 3,000 frames a week. It’s got a long and successful history in the holiday home market and continues to serve some of the sector’s major players, but I wanted to broaden its focus to include modular and the DIY market.

It wasn’t until early 2021 that I first crossed paths with Michael, and it immediately became clear that Euramax and MGI were an excellent fit. Euramax was already making windows and doors for modular manufacture and had capacity to do that much more. 1 2

There was also a lot of synergy between manufacturing for holiday homes, Euramax’s traditional strength, and doing so for modular housebuilders. Our conversations proved so positive that MGI didn’t just acquire Euramax, but I became MGI CEO, too.

Euramax gave MGI a solid foundation in modular thinking and our next acquisition was Rapid PVCU. Rapid is a 12-year-old PVCu fabricator in Doncaster, and acquiring them not only boosted our productive capacity, but also diversified our customer base. MGI doesn’t specialise in fenestration – we want to cover the whole spectrum of modular components and Rapid PVCU was another case where the synergies were too good to turn down.

They’re able to provide a complete package for newbuild customers, including expert technical advice, input on minimising costs and help with design, as well as supply and installation on time and in full. We’ve since brought in industry veteran Simon Bingham as Rapid’s Commercial Director, and his experience will be a huge asset in helping that side of the business expand.

The third of 2021’ big acquisitions was Barton Windows. Barton Windows is a 35-year-old aluminium fabricator

based in Barton-upon-Humber, North Lincolnshire. So, the most obvious thing that they bring to the table is the ability to cater to the aluminium side of the glazing market. Euramax could do that to some extent already – in fact we have launched Euralite, a range of cladding and decking products that combines all the benefits of aluminium with the sought-after aesthetics of timber. But Barton Windows expands that capacity even further, allowing us to better serve the needs of our customers.

Looking ahead into 2022, MGI will be continuing to seek out great new businesses that will help us expand our offering – our ideal acquisition is an experienced company operating some spare capacity that genuinely wants to sell. We’ll also be growing our range on the aluminium side, with the aim of adding balconies, steel components, and a range of other products commonly used throughout modular construction. It’s an extremely exciting time for us, and we can’t wait to see what the next twelve months holds.

For more information visit:

www.modulargroupinvestments.co.uk

Images:

01. Nick Cowley,

CEO,

MGI

02. Engaging with modular construction gives an optimum opportunity for the window and door sector

DATES FOR YOUR DIARY IN 2022

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

10 May Construction Productivity Conference London www.constructionproductivity.co.uk

This event will gather together those who have the skills to define a roadmap to create a climate for change. With statistics finding only 64% of the hours worked in construction deemed to be productive - the event will focus on new technologies, logistics, supply chains and materials management together with developing human resources to establish a workforce that is fit for the future.

21 June Tall Buildings Conference London www.tallbuildingsconference.co.uk

Back by popular demand, Tall Buildings Conference is returning in London and will assist engineers in understanding the common challenges associated with transferring standard engineering principles and knowledge from low-rise structures to tall buildings.

21 June Tall Buildings Awards London www.tallbuildingsawards.co.uk

Tall buildings present unique challenges in terms of both design and construction. Their sheer scale demands that particular attention is paid simultaneously to strategic and detailed issues. Tall Buildings Awards is taking place on 21 June 2022 in London and will highlight design and building technology innovation in the UK high-rise sector.

05 July Climate Emergency Conference Manchester www.climateemergencyconference.co.uk

NEW for 2022 Climate Emergency Conference is designed to debate and share the work and ideas the construction sector is implementing to decrease the sector’s carbon emissions - to ensure the construction industry helps to tackle climate change and meet Government targets by 2050.

20-21 Sept Offsite Expo

CBS Arena, Coventry www.offsite-expo.co.uk

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

20-21 Sept Offsite Connect CBS Arena, Coventry www.offsiteconnect.co.uk

Offsite Connect is an interactive Forum which offers a structured, highly effective way for buyers and specifiers to meet with new and existing offsite industry suppliers exhibiting at Offsite Expo. The Forum is aimed at senior personnel with an influence over procurement decisions or specifications with live projects or a significant pipeline.

20 September Offsite Construction Awards CBS Arena, Coventry www.offsiteawards.co.uk

The Offsite Construction Awards will reward outstanding examples of prefabrication and factory-based methods, products, systems and disciplines that increasingly strive to develop a sustainable, streamlined and cost-effective way to deliver a better built environment. ENTRY DEADLINE: 27.05.22

12 October Structural Timber Awards NCC, Birmingham www.structuraltimberawards.co.uk

Returning for its eighth year in Birmingham, there has already been a large amount of attention focused on the 2022 Structural Timber Awards. The Awards once again will reward excellence, celebrate expertise in timber technology and the ways it contributes to an attractive, energy efficient and sustainable built environment. ENTRY DEADLINE: 10.06.22

INDUSTRY ENEWS INCLUSIONS

Our monthly eNews enables you to keep the offsite sector updated on your product/company developments. Each newsletter features up to eight news stories and can cover a variety of offsite technologies. With a circulation of approx. 40,000 these monthly communications provide the ideal opportunity for you to reach your target audience.

Our offsite portfolio includes an abundance of profile-raising opportunities and this is just one way you can get involved!

For more information contact a member of our team on 01743 290001

ALIGN YOUR PRODUCTS AND SERVICES WITH THIS INCREASINGLY IMPORTANT SECTOR

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