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OFFSITE DEDICATED TO OFFSITE DESIGN, MANUFACTURE & DELIVERY | ISSUE 18 JULY/AUG 2019 | £4.95

SHAPING THE FUTURE OF UK ADVANCED MANUFACTURING

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SEISMIC CONSORTIUM Trailblazing and transforming the way new schools are designed, procured and built

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OFFSITE EXPO 2019 All the latest speakers, developments and details at this year’s premier offsite event

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THE DIGITAL RIVER Graham Cleland, Berkeley Modular and how to control the design and build cycle

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TRANSFORMING THE WAY THE WORLD WORKS


WELCOME

PUBLISHING FOLLOW US ON TWITTER UNDER: Twitter.com/ExploreOffsite ADVERTISING ENQUIRIES PLEASE CONTACT: Julie Williams // T: 01743 290001 E: julie.williams@offsitemagazine.co.uk BACK ISSUES VISIT: www.offsitemagazine.co.uk FRONT COVER EOS - Advanced Manufacturing Building

PRINTED ON: PEFC 16-33-576 paper stock by Buxton Press PUBLISHER: Offsite Magazine is produced and published by Radar Communications: ©Radar Communications Ltd. Radar Communications Ltd, 5 Darwin Court, Oxon Business Park, Shrewsbury, Shropshire. SY3 5AL T: 01743 290001 www.radar-communications.co.uk For offsite enquiries please contact: E: info@offsitemagazine.co.uk DISCLAIMER: The content of Offsite Magazine does not necessarily reflect the views of the editor or publishers and are the views of its contributors and advertisers. The digital edition may include hyperlinks to third-party content, advertising, or websites, provided for the sake of convenience and interest. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any advertising or products available from external sources. No part of this publication may be reproduced or stored in a retrieval system without the written consent of the publishers. All rights reserved.

DIGITAL WORLD NEW NORMAL Welcome everyone to the latest edition of the magazine. The last few weeks have seen some significant developments across the offsite industry including the launch of two new apps that will help close the digital divide between old and new ways of building. As we went to press the Seismic Consortium unveiled more details on the role it will play in transforming construction. Part of this will be an open source app enabling anyone from architects, planners and manufacturers to teaching professionals, school governors – even parents and pupils – to configure their new primary school building to meet their specific needs. The Seismic School app is a free web-based tool that has been developed to accelerate the initial design and feasibility stages and to speed up the arduous task of deciding how a new school should be built. Also unveiled recently was PRISM. Framed as the first ‘web-based app in the world operating on an open source basis and supported at a city government level’, PRISM provides an open data set for project benchmarking and an ‘intelligent design configurator that optimises residential design against available

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manufactured building systems’. It will be interesting to see what these cutting-edge slices of technology can do to increase the uptake of offsite methods in a world that increasingly looks to the digital world for answers. Elsewhere in this issue we hear about Swan Housing’s ‘Modular Design Guide’ and we introduce an international focus. Read how AEDAS Homes plan to revolutionise the way that homes are built on the busy Spanish Costa del Sol and we carry an exclusive from Skystone – one of the organisations at the centre of the construction of 6th Avenue Marriott AC NoMAD. When completed in the heart of New York City in 2020, it will be the world’s tallest modular hotel and a further showcase of what can be done with precision repeatable factory manufacture. You will be able to hear far more about a vast global wave of offsite projects at Offsite Expo, Coventry, 24-25 September, where the Offsite Summit, exhibition and masterclass sessions are shaping up to educate and influence the ways offsite manufacture is understood, specified and delivered. Find out lots more inside. Many thanks to all our contributors, advertisers and supporters. Enjoy…

Gary Ramsay

Consultant Editor Email: gary.ramsay@offsitemagazine.co.uk

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CONTENTS

COVER STORIES

42 | EOS Roundtable

P06 | SHAPING THE FUTURE OF UK

ADVANCED MANUFACTURING

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P26 | TRANSFORMING CONSTRUCTION WITH COLLABORATION & INNOVATION

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From their work on the pioneering Advanced Manufacturing Building at the University of Nottingham, to investment in their own state-of-the-art offsite factory facility and the development of groundbreaking steel systems, EOS is driving innovation in the UK manufacturing sector.

The results of the Seismic Consortium have been unveiled and have been hailed as a trailblazer for transforming construction. Richard Crosby, Director of construction consultants blacc, describes how this pioneering consortium could transform the way schools are designed, procured and built offsite.

P28 | OFFSITE EXPO -

P56 | CONTROLLING FLOW IN A

CATALYST FOR CHANGE

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Official show preview including full Explore Offsite Masterclass Programme, exhibition announcements, latest Offsite Connect news and details of the International Offsite Summit.

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Faced with the problem of having to explain a complicated notion it is sometimes helpful to draw on an analogy. Graham Cleland, Director at Berkeley Modular, applies this thinking to the design and build cycle and effective operation and maintenance of residential developments.

FEATURES

08 | Industry News

40 | Changing Housing Perceptions

CALLING ALL SPECIFIERS! ARE YOU LOOKING FOR THE LATEST OFFSITE INNOVATIONS?

Swan Housing Association is leading the way on modular housing and recently launched their own Modular Design Guide based on their learning from launching their own volumetric modular housing factory.

EOS recently hosted a roundtable event and discussed DfMA, the growth of digital design and how these new tools are playing a huge part in the growth of offsite construction activity using the myriad offsite technology options now available.

60 | A Vision of the Future

When it comes to offsite manufacturing, collaboration is king, says Dave Sheridan, Executive Chairman of ilke Homes, whose firm is at the forefront of delivering quality housing via offsite manufacture.

64 | Costa Gets Offsite Makeover

AEDAS Homes has just launched its latest modular project. Designed to respond to its exceptional natural surroundings and views of the Mediterranean Sea, Vanian Valley is the first large-scale offsite development on the Costa del Sol.

68 | Cladding: Expertise and Engineering

DIGITAL RIVER

NEWS News and developments from across the UK offsite industry and wider construction arena including: two new digital apps aiming to streamline offsite design and adoption, LoCaL Homes launch a range of kitchen and bathroom pods and the Government is warned about missing housing targets.

Andrew Way, Associate Director at the Steel Construction Institute (SCI), discusses issues surrounding light steel framing with continuous masonry cladding.

74 | A Game Changing Moment for Modular Construction

Last issue we reported on the world’s tallest modular hotel nearing completion in New York City (NYC). We follow up with a quick overview of the 6th Avenue Marriott AC NoMAD approach by Henry Mickleburgh, Executive Vice President at Skystone LLC.

78 | CLT – It’s here to stay

CLT has been the timber industry’s game changer since its conception and for good reason, yet the unpredictable events of the last couple of years show some refinement of the system is required. Rupert Scott, TRADA’s Membership and Marketing Manager, explains more.

86 | Beautiful Building

Elaine Toogood, Senior Architect, The Concrete Centre, illustrates how concrete helps deliver a bespoke, natural aesthetic and superb structural performance.

90 | Vita Student Westgate

Intelligent Steel Solutions (formerly known as Icarus LSF) used modular methods during the construction of Vita Student Westgate, as well as Trimble’s Tekla software to assist with the design and manufacture of the building.

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E


COVER STORY EOS

SHAPING THE FUTURE OF UK ADVANCED MANUFACTURING

From their work on the pioneering Advanced Manufacturing Building at the University of Nottingham, to investment in their own state-of-the-art offsite facility and the development of ground-breaking steel systems, EOS is driving innovation in the UK manufacturing sector. and supply of the infill walling steel framing system (SFS). Building information modelling (BIM) technology enabled the design to be tested in a digital environment where the proposed construction solution could be changed at minimum cost. In line with the sustainability ethos of Nottingham University, design for manufacture and assembly (DfMA) protocols helped to identify, calculate and eliminate waste or inefficiency in the structural design. By manufacturing offsite, EOS were able to develop as much of the finished product as possible in the factory, ultimately minimising on-site labour.

1 With manufacturing going through a technological revolution, the flagship research facility at the University of Nottingham has been developed to help future-proof UK industry in a competitive global market. Siemens UK CEO, Juergen Maier officially opened the Advanced Manufacturing Building on 07 December 2018. With a total research portfolio of £80million, the nationally significant development consolidates the University’s manufacturing science and technology capabilities, expertise and industrial support. The new landmark building has the capacity to house 699 staff, students and researchers, helping to train and provide the next generation of industry

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pioneers. It is therefore fitting that one of the UK’s leading innovators in the offsite arena, designed, engineered and manufactured the structural system offsite. The building adopts low-energy design techniques to create a sustainable solution without compromising the need for an adaptable and pleasant working environment. Low-energy design features include louvres for ventilation, light shelves that allow natural illumination into the building, photovoltaic cells and highperformance insulation for heat and sound. To create the high-performance external envelope, EOS completed the design, engineering, manufacturing

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With a culture of continuous improvement, EOS have invested in an advanced factory facility and fabrication plant to be self-sufficient in the manufacturing of ancillary parts such as angles, brackets, windows and cills. Ongoing investment in research and development, combined with the latest manufacturing machinery and digital technology, has resulted in the launch of a new system approach for the offsite sector. Introducing the New and Revolutionary Thrubuild® System The EOS Thrubuild® loadbearing system uses offsite manufacture and the latest testing to deliver structures faster – with assured performance built-in. Developed in collaboration with Etex Building Performance brands, EOS, Siniat, and Promat, the system makes use of the latest products, technical know-how, and manufacturing excellence of the Etex Building Performance team. The loadbearing, light steel ‘through the


COVER STORY EOS wall’ system, has been developed to form the structure of low to mediumrise buildings, up to nine-storeys, and fully tested with boarding and insulation for confidence of design performance. The light steel framework is panelised in the factory and delivered to site for assembly. Partial boarding of these frames can also take place offsite depending on the system and your build process. A Different Structural Approach Designing with light steel structural systems is not complex but requires a different approach. It is based on transferring loads throughout the building and through as many walls as are practical. Internal and external walls become fundamental parts of the primary structure, rather than just infill pieces that only carry their own weight and directly applied loads. As a result, fire resistance requirements often increase compared to nonloadbearing steel as each element must be protected for the structures’ period of resistance, rather than solely as fire compartments. System Overview The EOS Thrubuild® loadbearing system has been developed as an integrated solution, using a range of light steel framing, Siniat Weather Defence external sheathing board, and Siniat Frameboard, an internal plasterboard exclusively developed for the EOS loadbearing systems by Siniat, a world leader in plasterboard materials. These integrated systems have been tested and assessed for compliance with the latest regulations and standards to ensure robust and reliable design performance. EOS light steel framing features coldrolled galvanised light steel sections in a range of depths and gauges. C-sections are swaged for a flat surface finish. By considering all components, systems can be relied upon to offer excellent fire, acoustic and thermal capabilities to suit the needs of UK single and multi-residential construction. All systems have also been engineered for structural performance to the latest Eurocodes. Design performance is achieved using combinations of boarding and insulation. Almost all building arrangements can be achieved, and non-loadbearing drywall systems can also be used to sub-divide space following initial construction of the loadbearing building system.

2 Steve Thompson, Managing Director, EOS, said of the product development: “The combination of expertise from the Etex Building Performance group in drylining, external sheathing and steel framing systems, as well as passive fire protection, means that we are uniquely positioned to bring together these elements to create a range of tested and warrantied Thrubuild® systems. Meeting building performance requirements for fire, thermal, weathering, acoustics and airtightness – the newly launched Thrubuild® Systems provide an ‘all in one’ solution with crucial time and costs benefits.”

By combining strength, durability and precision engineering, the EOS product portfolio offers broad parameters to explore innovative offsite solutions and optimise value engineering – for more information visit: www.eos-facades.co.uk

Come and see us at OFFSITE EXPO - STAND G17 Images: 01. Advanced Manufacturing Building, Nottingham 02. The Thrubuild® loadbearing system provides an ‘all in one’ solution providing crucial time and costs benefits

BENEFITS OF LIGHT STEEL STRUCTURES FOR DEVELOPERS High Strength to Weight Ratio: reducing total load by up to 60% compared to timber and concrete saves on foundations and is suitable for construction on brown field sites, or pre-existing buildings. Panelisation: offsite panels reduce site labour costs, reduce construction waste, cut the project cycle time, and improve quality with external boards factory fitted. Reduced Project Programmes: shorter construction time reduces financing costs and narrows period of construction liability. On larger schemes you can be shaving months from programmes compared to concrete builds. Winter Builds: panelised factory assembled products are not weather dependent and combined with fast installing products such as Siniat Weather Defence means the site can be made weathertight earlier, allowing internal trades to commence. Earlier Completion and Budget Savings: a light steel structural system’s shorter construction cycle means equipment can move on and off site more quickly lowering crane and scaffold costs and site prelims and labour costs. Lower Insurance: light steel is non-combustible.

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UK INDUSTRY NEWS operate at scale and align to currently available forms of offsite methods. PRISM has two parts to its functionality – an open data set for project benchmarking and an intelligent design configurator that optimises residential design against available manufactured building systems. The app’s development included extensive consultation with the architectural and manufacturing communities and has been led and co-sponsored by Greystar, L&G, L&Q and TfL.

PRISM app Targets Offsite At a special London launch event Cast Consultancy unveiled a new digital app that it has been working on for the last 20 months. Developed in partnership with Bryden Wood, PRISM is the first web-based app in the world operating on an open source basis and supported at a city government level. It was a concept

borne out of early conversations between Cast CEO, Mark Farmer and London Assembly Member, Nicky Gavron. Gavron’s 2017 report, ‘Designed, Sealed & Delivered’ made specific recommendations on how London could better promote precision manufactured homes, building on recommendations made in The Farmer Review. Mark Farmer developed these conversations with the Greater London Authority’s Housing & Planning team and proposed a technology led innovation that can

The open-source program lets users design a multitude of different structures on a specific site, as well as export 3D geometric drawings to other BIM programs and download a PDF with key project metrics. Jami Cresser-Brown, Director at Bryden Wood who led the creation of the app, said: “Normally this process would take a matter of weeks, maybe even months, depending on the size of the scheme. But using PRISM this whole process can be taken in under 15 minutes.” The PRISM team is actively looking for feedback. Any manufacturers interested in sharing system characteristics to be included in next versions of the PRISM are encouraged get in touch. The intention is for this to be a resource that grows over time and supports the data driven approach to housing delivery in London. The app is free and easy to use and is available at www.prism-app.io Source: www.cast-consultancy.com

AIMCH Project Set to Revolutionise New Homes Industry leaders and stakeholders recently joined together to learn more about the Advanced Industrialised Methods for the Construction of Homes (AIMCH) project – the collaborative innovation project with the ambition to deliver high quality offsite homes faster, more reliably and at the same cost of masonrybuilt homes. Plans include how to identify and develop industrialised offsite solutions needed to meet current and future housebuilding demands. These will be trialled on live housing projects, with successful methods then being commercialised and brought to market in volume. The event, which took place at the RIBA’s London headquarters on 20 May 2019, was chaired by Sir Edward Lister, Chairman of Homes England and the AIMCH Stakeholder Group. The event gave everyone a deeper understanding of the project and helped to build relationships between stakeholders and organisations. Delegates, including representatives from Homes for Scotland, RICS, Cast Consultancy, CITB and the NHBC, also heard from AIMCH Project Director Stewart Dalgarno and Oliver Novakovic, Technical and Innovations Director at project partner, Barratt Developments. Stewart Dalgarno, AIMCH Project Director and Director of Product Development at Stewart Milne Group said: “The housing sector faces many challenges in meeting

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government targets, including skills shortages, poor productivity and low affordability. Housebuilding must change, and AIMCH is an exciting, challenging and game-changing project which is well placed to succeed in transforming the way homes are built. “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 and viably. This event has been an excellent chance for project stakeholders to get a deeper understanding of the desired outcomes, give their input and learn from each other.

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The feedback received today was extremely valuable and will flow back into the project.” Sir Edward Lister (pictured in yellow tie) added: “This event has got stakeholders and industry leaders excited about the huge potential of the AIMCH project, which we hope will revolutionise the housing sector. It was also fantastic for everyone to hear how it will deliver wider benefits in terms of jobs, investment and growth. I’m looking forward to watching the project progress.” Source: www.aimch.co.uk


Bespoke Framing Systems Steel Solutions Without Compromise

Hadley Group provides a pre-panelised stand-alone steel frame structure which is a lighter and easier to erect alternative to steel or concrete primary frames and offers distinct advantages over timber frame construction within the residential property market. Properties of up to four storeys can be quickly and effectively produced. Spans of up to 6m offer the potential to eliminate internal load bearing walls and thereby provide more options for internal space planning.

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UK INDUSTRY NEWS CITB Agrees Offsite Funding

CITB has agreed £1.2million funding for two projects that will increase the skills capacity for this growing sector in education, for school leavers and among industry trainers. The projects are being led by the Construction Scotland Innovation Centre (CSIC), and the Manufacturing Technology Centre (MTC). As a result of this investment, industry and education will have free access to a range of ‘standardised, innovative and blended’ learning materials. Trainers in education and industry will be able to upskill themselves in offsite manufacturing and construction, alongside an outreach programme for secondary schools to show a new generation the career opportunities involved. The projects will be pioneering a collaborative approach involving employers, providers, contractors and leading innovation organisations that will bring new, free, innovative training materials to industry. CSIC will help establish an offsite construction competency framework, while both projects will draw from existing training materials and industry knowledge to create the new content, mapping it to current training and qualifications. Teaching support and upskilling programmes for offsite trainers will be developed, with sessions taking place across the country to upskill trainers in key offsite roles and functions. Steve Radley, CITB Strategy and Policy Director, said: “Offsite construction creates a range of exciting new skills needs and opportunities, including in assembly, digital technologies and installation. We’re looking to build these into training at both entry level and also to enable upskilling within the industry, because getting this right can mean a more multi-skilled, diverse and productive workforce.” Rohan Bush, CSIC Head of Public Partnerships and Future Workforce, said: “It is time to think differently about construction, because carrying on as we

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SES Engineering Services Win Industry Award

are is simply not an option – our industry needs to modernise. Offsite construction can efficiently deliver a high quality, mass-customisable product that is technically advanced, offering social, environmental and economic benefits. But to ensure that offsite becomes mainstream, we need a workforce with the necessary skills – and that’s where these projects come in.” The MTC’s Ian Buckingham, Construction Skills Manager, added: “The primary purpose of this project is to develop the capability and capacity of the construction industry training network. This will be achieved through the development of a common and consistent set of training materials that are freely available for trainers, and through the upskilling of existing and new trainers. The MTC is at the forefront of emerging technologies, productivity and efficiency and we are very pleased to provide the construction training sector with the support it will need to drive construction forward.” On completion of the project, to ensure there is the widest access to these training materials partnerships have been formed with the National Open College Network (NOCN), Structural Timber Association, Laing O’Rourke, Transport for London (TfL), the Construction Wales Innovation Centre, Class Of Your Own, Ministry of Building Innovation and Education, City of Glasgow College and Edinburgh Napier University’s Institute for Sustainable Construction. Through their networks resources will be available to major contractors, their supply chains and more than 600 education and training providers in England, Wales and Scotland. Source: www.cs-ic.org

OFFSITE EXPO INDUSTRY SUPPORTER

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SES’s innovation in offsite technology and manufacturing has earned the specialist contractor an industry accolade at the recently held Constructing Excellence North East Awards, in the Offsite Project of the Year category. This latest accolade was awarded to SES in recognition of the work it has done, along with project partner BakerHicks on a prestigious £94million Aseptic Manufacturing Facility in Barnard Castle, Durham, for global pharmaceutical company, GSK, due to complete in November 2019. Currently in the commissioning phase, the new 11,500m2 Q Block facility will allow GSK to add further to its broad range of sterile biopharm products for various treatments. It will also be a flagship project for the pharmaceutical company around the world. GSK was committed to embracing extensive prefabrication and offsite technology from the outset of the project and understood the importance of early contractor engagement and getting SES on-board at the earliest opportunity. Steve Joyce, SES Business Director North and Scotland, said: “GSK is a forward-thinking company which identified and appreciated the importance of getting SES onboard at the earliest opportunity. This early engagement coupled with our BIM Level 2 experience and bespoke offsite capability, via our offsite manufacturing facility Prism, allowed us to influence the M&E design from the outset of the project. “As a result, a significant 60% of the MEP services will be manufactured offsite which meets a key target of GSK’s brief to replicate the building elsewhere in the world. I believe Q Block is an excellent example of offsite construction and engineering being used to best effect and I am delighted that this was also recognised by the industry and the Constructing Excellence North East judging panel.” As well as the M&E services benefiting from offsite technology, 40% of the building’s shell (including precast units, wall systems and steel framework) and 95% of a 2500m2 cleanroom will be manufactured offsite. Source: www.ses-ltd.co.uk


UK INDUSTRY NEWS Norbord Explain Challenges to Gove

LoCaL Homes’ Add Pod Range

LoCaL Homes has launched an innovative range of kitchen and bathroom pods to add to its closed timber panel solution. LoCaL Homes, Accord Housing Association’s offsite housing manufacturer, will deliver the first of its kitchen and bathroom pods to roll off the production line in Walsall, to a site in Wolverhampton. The pods will be fully-fitted before they leave the factory and they will be transported to site ready to be incorporated into a range of house types. The pods will be used for a wide range of affordable homes, including apartments and houses.

Secretary of State for the Environment Food and Rural Affairs, the Rt Hon Michael Gove MP, met with one of the UK’s leading wood panel producers to hear about the challenges they’re facing sourcing their main raw material. Gove was given a guided tour of Norbord’s operations in Cowie, Stirlingshire, accompanied by local MP Stephen Kerr, who also chairs the All Party Parliamentary Group (APPG) for the wood panel industry. Norbord and other leading manufacturers who are members of the Wood Panel Industries’ Federation (WPIF) have warned that a major government rethink is required to help the industry satisfy demand for its products, in order to secure thousands of jobs and help the UK face up to its housing crisis. A recent report carried out on behalf of the APPG for the wood panel industry concluded that wood availability will decrease dramatically within the next decade. The strain on the UK’s wood basket is being exacerbated by renewable energy subsidies and is creating real uncertainty for wood panel manufacturers while endangering the supply of key materials in the construction and housebuilding sectors. Steve Roebuck, Director of Environmental, Health and Safety at Norbord, said: “I’m very pleased that Mr Gove took time to visit our site and listen to Norbord’s concerns. He certainly took on board our message that the UK’s wood supply is now at a critical point due to demand from heavily subsidised biomass for energy. “We’re not against the use of wood for energy, but continuing to use subsidy to drive wood towards

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energy is putting undue pressure our domestic wood supply. This threatens industries, such as construction and furniture manufacture, which rely on wood panels and sequester carbon for generations. A point that I think all parties agree on is the pent-up demand in the requirement for low cost affordable housing. If you’re not going to have wood panels manufactured in the UK, you’re going to import them, and you’re not going to make them out of steel, so this is a critical area that everybody is agreeing on – we have to build those houses and, to build those houses, you need woodbased panels. That’s 50 per cent of our business.” Stephen Kerr, MP for Stirling and Chair of the APPG for the wood panel industry and expert working group, added: “I have the privilege of chairing the APPG for the wood panel industry, a sector which 7,500 British jobs are directly supported by. In my own constituency alone, 250 jobs are created and sustained by the Norbord plant directly, with another 250 employed by local supply chain partners indirectly. “This industry has the capability to increase production to meet the UK’s demand for wood panel products and to do so with no reliance on imports of wood from elsewhere in the world. However, this is only possible if it has enough wood to sustain and grow its manufacturing capability.” Pictured Left to right: Stephen Kerr, MP for Stirling and Chair of the APPG, Steve Roebuck, Director of Environmental, Health and Safety at Norbord, Rt Hon Michael Gove MP. Source: www.norbord.co.uk

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Alan Yates, Deputy Chief Executive at Accord said: “Following on from LoCaL Homes’ move to a new and larger manufacturing facility in Walsall last year, the development of our new pods product takes the LoCaL Homes housing solution to a whole new level. Manufacturing fully-fitted kitchens and bathrooms before they’re delivered onsite speeds up the house building process, and sees a higher percentage of the homes being built within a quality controlled factory environment. I am really excited about the launch of these new products.” Alan Yates was also awarded an OBE for his services to housing in the Queen’s Birthday Honours list 2019. It was bestowed on Alan in recognition of his dedication and ongoing work in the housing industry, in particular his commitment to providing affordable homes. Alan said: “I am delighted to have received this honour and I hope that it inspires others in the housing sector to innovate, in order to provide better homes and services to our customers. Building good quality, affordable houses that people can call their home is really important to me, and doing this by using sustainable building and construction methods is something I am very passionate about.” In addition to his role at Accord, Alan is also Chairman of the Sustainable Housing Action Partnership (SHAP), the Chairman of the NHF Regional Investment Group, a member of the NHF Great Homes Group, and Associate Non-Executive Director of Walsall NHS Healthcare Trust. He was also the former Chairman of Energiesprong UK and a housing advisor to The National Trust. Source: www.accordgroup.org.uk


UK INDUSTRY NEWS It All Stacks Up for ilke

Manchester on 25 June, Dave Sheridan, Executive Chairman, ilke Homes (pictured), said that housing associations could speed up delivery and improve quality by embracing offsite manufacturing. The new guide, entitled ‘It all stacks up’ explains how precision-engineered homes are far greener and more energy efficient than typical new build construction. It goes into detail about volumetric housebuilding – where houses are engineered in a factory, with complete modules being transported to sites and then assembled. Official data from Homes England for the year to 31 March 2019, shows there were 45,692 housing starts on site and 40,289 housing completions delivered through programmes managed by Homes England outside of London – the highest for nine and four years respectively. Yet only a tiny fraction of these were built using offsite – something many experts believe needs to change. “Housing associations are now being recognised for their ability to deliver at scale and to play a vital role supporting those most in need,” said Dave Sheridan. “We’re keen to help them build better quality housing and to do so quicker, ensuring that together we support the government’s housing delivery ambitions.

ilke Homes has launched a guide explaining how factory-built homes for families and young professionals could ease the housing crisis. Speaking at the Chartered Institute of Housing (CIH) conference in

“We are seeing interest growing substantially in the market and with such scale, housing associations have a crucial role to play in supporting investment into

more factories using the same digital technology and precision engineering that we employ in Yorkshire. Our guide aims to demystify the process and share some of what we’ve learned to help break down some of the remaining barriers to entry.” Sheridan, who has more than 30 years’ experience in the housing sector, believes that there is an opportunity to step up delivery of affordable homes deadlines and use grant funding in a clever way. Being only 21 months out from the original Shared Ownership And Affordable Homes Programme (SOAHP) deadline, if an Registered Provider (RP) hasn’t started on a scheme yet, they could even complete by March 2021, for example, if they made it a volumetric scheme. To deliver more homes faster, RPs can take advantage of two key features of volumetric delivery highlighted in the new guide: a cash profile that lends itself to alignment with grant payments and faster, more certain delivery to meet completion deadlines. The new guide includes contributions from key experts in and around the housing sector, including Places for People, NHBC, Trowers & Hamlins and HTA Design, who share tips and learnings for using volumetric and working with a manufacturer. The guide to volumetric housebuilding can be downloaded at: https://bit.ly/2xF9GHx Source: www.ilkehomes.co.uk

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UK INDUSTRY NEWS Ikea & Skanska’s Housing Move to the UK Welcomed

increased efficiency. His aim is to create homes which suit the pockets of those on average incomes. “Modern methods of construction can deliver on all of these, which is why investments in offsite solutions have increased significantly,” he said. “BoKlok homes are built using a smart, industrialised and efficient process that produces high-quality, environmentally sensitive housing at a low price,’ he explained. BoKlok has nothing to do with ‘flat-packs’, it is about completed quality homes manufactured offsite.” Buying materials in large quantities enables the IKEA/ Skanska marriage to benefit from economies of scale and it offers, in true Ikea style, a small selection of clean line designs which reduce upfront costs. Its one to four bedroom apartments and terraced houses are finished in white paint and plain tiles. Its Swedish incarnations all benefit from solar panels.

A plan by Swedish home décor giant IKEA and construction wizard Skanska to bring their low cost sustainable offsite housing model to the UK has been welcomed by insulation specialist Actis. The company has built 11,000 homes so far in Sweden, Norway and Finland using sustainable offsite manufacturing methods, giving more people the opportunity to own a quality, sustainable home, at a lower price than the current market value. Speaking at Housing 2019 in Manchester. BoKlok UK vice-president Henrik Johnnson stressed key factors to the success and sustainability of the future housing market are more housing choice, improved quality and

BBA Certification for FastClad

“In Sweden, our calculations show that a BoKlok multifamily house generates half the carbon emissions compared to the average of a newly produced multifamily house,” added Henrik. “We will use the same means of production for the UK market and hence it is a reasonable to think that the result would be the same in the UK. Transportation of the modules is a very small part of the total emissions. “In a world with finite resources we do as much as possible to minimise our impact on the environment, which is why we build in wood – the most climate neutral and natural building material. Building in a factory lowers our environmental impact, especially as we use timber frames. We recycle most of our leftover materials – less than 1% gets thrown away. And our carbon footprint is less than half that of normal building projects. All of this makes us more sustainable and more cost effective.

modern lightweight methods of construction with the appearance of traditional brickwork. Manufactured in a purpose built factory and delivered as pre-bonded masonry panels, complete with fixings and pointing mortar, this non-structural, weatherproof cladding system can be quickly and easily secured to timber, steel-framed, masonry or concrete structures without the need for scaffolding or specialist tradesmen, saving contractors both time and money. Suitable for both onsite and offsite projects, FastClad is frequently used on entire facades, soffits, balconies, infill and recess panels, as well as for re-cladding existing buildings.

Advanced Construction Systems Ltd has received updated certification from the British Board of Agrément (BBA), reflecting recent amendments to the Building Regulations, for its innovative FastClad lightweight brick slip system. A well-established and proven prefabricated brick slip cladding system, Fastclad combines all the cost and efficiency advantages of

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As a versatile system that can use virtually any facing brick, FastClad has also featured on several awardwinning architectural projects, where a flexible brick slip solution has been required to provide an exciting individualistic finish or a seamless match with existing brick blends, sizes and bond patterns. With independent approval from the BBA, one of the UK’s leading certification bodies, architects, designers, contractors, offsite manufacturers and building

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“Our housing areas are relatively small with leafy areas where people can meet in a natural way. They are always close to public transport, shops and other public amenities. We help our customers live more sustainably, whether that means saving energy and water or how they can find cleaning products without any harmful chemicals. Perhaps most important of all, we don’t build any unnecessary square metres. We create smart space, not show-off space. Every square metre we don’t build reduces our environmental impact. Our goal is a low price with meaning. That’s something entirely different from building cheaply. “We build most of our houses inside, which reduces the risk of weather damage. We build with care to show respect for the people who will move in and we build smart using natural and environmentally friendly materials. Because we’ve perfected our process we are one of the fastest companies in the industry. No one else can build and deliver a quality home, ready to move into as fast as us. As soon as we’ve found the right piece of land we don’t waste any time. This means less disruption for local residents and fewer risks for the builders.” Actis Regional Sales Director Jemma Harris is particularly excited about the latest forward thinking offsite specialist. “We welcome initiatives aimed at addressing the housing crisis and the construction industry skills shortage while improving the environment. Here is another wonderful example of construction organisations being proactive, thinking outside the box and looking at new and innovative ways of creating the homes we need.” Source: www.insulation-actis.com www.boklok.co.uk

control have additional reassurance that FastClad has undergone comprehensive assessment including onsite evaluations and rigorous tests relating to durability and fire. It is manufactured to a Quality Plan, which is agreed with and regularly audited by the BBA. “BBA certification provides well-respected assurance of suitability, quality and reliability, which strengthens our reputation as a trusted supplier of a brick slip system that meets the requirements of architects, specifiers, contractors and offsite manufacturers,” said Pete Stephenson, General Manager of Advanced Construction Systems Ltd. FastClad lightweight brick slip panels are easy to install and require little maintenance. They are certified for use, where regulations allow, at up to 42m in height. Left to right: Pete Stephenson, General Manager Advanced Construction Systems Ltd, Wendy Ajuwon, Marketing Manager at the British Board of Agrément and Shaun Crosskey, Business Development Manager at Advanced Construction Systems Ltd. Source: www.fastclad.co.uk


Rapidres is an innovative offsite fastrack modular precast concrete build system, delivering robust traditional style construction and significant programme savings. It is ideally suited to multi-storey projects such as: • Apartments • Student accommodation • Hotels • Social housing • Custodial

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UK INDUSTRY NEWS Blackburn Housing Boost

Barratt Acquire Timber Frame Manufacturer

Barratt Developments has completed the acquisition of Oregon Timber Frame Ltd, one of the UK’s largest timber frame manufacturers. In 2018 Barratt Developments announced new targets of volume growth of 3-5% over the medium term, supported by a target of building at least 20% of its homes using an element of offsite construction, including timber frame, by 2020. Seventy three affordable modular homes are to be created close to Blackburn town centre as part of a deal between Places for People and Homes England. Funded through Places for People’s Strategic Partnership with Homes England, the development will bring new timber-framed homes to a site off Alaska Street, just south of Blackburn town centre. All of the two, three and four bedroom homes will be created offsite at Places for People’s Modularwise factory in Wales, using pre-manufactured modular construction techniques. Places for People was selected as one of Homes England’s first strategic partners in July last year, receiving £74million in funding to help deliver 2,603 additional affordable homes by 2024. The Alaska Street development is being created as part of Places for People’s broader strategy which has seen it increase its commitment to offsite construction – including its recent announcement of a partnership with ilke Homes, the modular sector’s biggest ever deal. David Cowans, Chief Executive of Places for People, said: “We are delighted to announce more details of this development, which will pave the way for the creation of affordable homes for the local community in Blackburn. Our recent efforts show how Places for People is embracing modern methods of construction as we strategically invest in modular, finding new ways to deliver better, well-designed and affordable homes in the process.”

The investment from Homes England comes following the organisation’s increasing support of offsite construction. Chris Groves, General Manager for MMC at Homes England explained: “MMC have the potential to be significantly more productive than traditional building methods and greatly increase the pace at which new homes are delivered. In October, Homes England published its strategic five year plan that makes the take up of MMC a requirement for developers on our sites. We use strategic partnerships, like that with Places for People, to support our partners in adopting MMC and help create affordable homes that towns like Blackburn need.” Councillor Phil Riley, Executive Member for Growth and Development at Blackburn and Darwen Council, added: “This project will bring affordable, modern homes to Blackburn, and increase choice for people in the borough. It will also contribute to the wider regeneration of the area and add to the great home building taking place. The redevelopment of Alaska Street has been a priority for the regeneration of South Blackburn for a number of years and we are delighted that work can now progress.” Places for People is a leading placemaker in the UK. It believes that places work when they work for everyone, and these places are designed for the long term, with heart and soul, and sustainable value at their core. Taking a commercial approach to delivering social impact is what makes Places for People different. Source: www.placesforpeople.co.uk

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Over the last three years, Barratt has built 5,500 homes using timber frame construction. It currently uses it in the majority of residential properties it builds in Scotland and is increasing its use across England and Wales. Oregon is one of Barratt’s key timber frame suppliers. Following the acquisition, Oregon will remain based in Selkirk, Scotland where its management team will continue to lead the business, complementing the Barratt operations in Scotland. The acquisition has no material effect on the board’s expectations for the financial year. Steven Boyes, Chief Operating Officer of Barratt Developments, said: “We are delighted to announce that we have successfully acquired Oregon Timber Frame, one of the leading timber frame manufacturers in the UK. Barratt is committed to increasing the number of homes we build using offsite construction as part of our overall volume growth aspirations and to mitigate the current skills challenges facing the industry. Oregon is the perfect company to help us do that, with a highly experienced management team, a skilled workforce and a highquality product.” Rod Lawson, Chairman of Oregon, added: “We’re very proud of what we have achieved over the last two decades, building a successful company with a fantastic workforce. Now we welcome the next chapter with Barratt who are as committed to quality as we are and have exciting plans for the future of both of our businesses.” Source: www.barratthomes.co.uk


UK INDUSTRY NEWS Balfour Beatty Awarded £37M Hospital Contract Balfour Beatty has been awarded a £37million contract to deliver two community hospital facilities in Scotland on behalf of hub North Scotland, Badenoch & Strathspey Community Hospital and Health Care Centre in Aviemore and the Skye, Lochalsh and South West Ross Community Hospital at Broadford on Skye. The contract will see Balfour Beatty construct two new 24 bed facilities which, on completion, will provide in-patient and X-ray services for the community in Skye and an urgent care facility, GP practice, in-patient and Scottish Ambulance Service facility in Aviemore. In line with Balfour Beatty’s commitment to reducing onsite activity by 25% by 2025, the facilities energy centres which will provide heating, electricity and water, will be constructed offsite to improve safety while enhancing productivity and efficiency on site. Balfour Beatty was appointed as main contractor for the delivery of these works following close collaboration with hub North Scotland throughout the 18-month preconstruction phase ensuring the provision of the most cost-effective and high-quality design solution. In addition, Balfour Beatty Ground Engineering will apply its ground engineering expertise and specialist geotechnical knowledge to deliver the project’s crucial ground engineering requirements including concrete driven piles.

Birmingham Launch New Modular Design

Hector MacAulay, Balfour Beatty’s Regional Managing Director of Scotland and Ireland, said: “At Balfour Beatty, we are deeply committed to bringing value to the communities in which we operate. “Our wealth of experience and expertise in community infrastructure, along with our continued focus to deliver high quality projects to budget and on programme, will ensure that the Skye and Aviemore hospitals will service the surrounding communities for years to come.” Iain Stewart, NHS Highland’s Chief Executive, added: “The start of construction of these two hospitals marks another exciting step forward for NHS services in both Badenoch & Strathspey and on Skye and crucially supports our efforts to modernise and transform the

BMHT delivery averages 400-500 homes per annum, compared with around 200 through the 50 Registered Providers operating in the city. The City’s housing need is 89,000 additional dwellings between 2011 and 2031 including around 33,800 affordable dwellings. Smaller sites form an important part of the BMHT programme, and this work has focused mainly on former garage sites and other sites that include former municipal depot sites and surplus amenity land/former drying areas. In order to render these difficult sites suitable for development, officers have developed an innovative housing typology that meets the current internal space standards (NDSS), and protects the amenity of neighbouring residents. Usually housing developments meet a number of design and layout criteria in order to meet planning requirements including:

Birmingham Municipal Housing Trust (BMHT) – the Council’s own vehicle for delivering rented and sale homes – is the largest provider of affordable homes in both Birmingham and the wider West Midlands area. To help boost the levels of new housing BMHT Modular is set to increase the supply of social housing through offsite manufacturing techniques.

• • • •

Compliance with nationally described space standards (NDSS) Parking for private vehicles (usually a minimum of 100% per dwelling) Site access and turning within the site compliant with highway authority requirements A private rear garden of a prescribed size (m2) or in the case of apartments, an area of private and shared amenity space.

delivery of healthcare in both regions. We very much look forward to delivering high-quality sustainable services that the communities can be proud of. I would also like to take this opportunity to recognise the significant contributions that both communities have made in helping to develop the wider health and social care redesigns.” Balfour Beatty will engage with the local supply chain across both regions to create local jobs and boost the local economy. At construction peak, Balfour Beatty will employ a workforce of 200 including the recruitment of two trainee construction managers. Works are due to commence this summer with completion expected in spring 2021. Source: www.balfourbeatty.com

The Birmingham Modular Home was designed to a very high standard and built in partnership with Coventry based Just Solutions Ltd. The two bedroom, four person 80sq m home was delivered to site on 10 June 2019. Unlike many modular solutions, this property was ready for occupation within two hours following delivery. The home was manufactured using rolled steel with insulated cladding, aluminium framed windows and doors. It was constructed in a quality controlled factory environment and then delivered to site and fixed directly onto concrete pads. In terms of guarantees on structural issues and mortgageability, all BMHT modular homes will be registered for BOPAS. A minimum life of 60 years will be guaranteed but it is expected that Birmingham’s new range of modular homes will far exceed this with their inherent structural stability and ability to replace components easily. The estimated cost of building a new home using a modular approach is comparative to BMHT Traditional construction. The first three phases of modular development will be procured via the Council’s procurement portal InTend on sites across the city. Source: www.birmingham.gov.uk

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UK INDUSTRY NEWS Lindapter® Contribute to CitizenM Bradford-based Lindapter® supplied its Hollo-Bolts as a solution to the modular construction of a boutique hotel in Seattle. Modular construction is a key design and delivery method that has been adopted by Netherlands-based hotel operator citizenM, who have brought their steel-framed modular hotels to New York and Los Angeles. Polcom Group, specialist offsite modular manufacturers, were appointed to build 228 modular units for the hotel. They identified that they would need to modify their normal production and assembly process to meet US building practices and standards. Due to time constraints the traditional method of connecting units together on-site by drilling and bolting was not chosen, whilst hot welding risked damaging the critical waterproof membrane that protects each module. Special steel structural shear plates were designed and added to the steel enclosures of the modules during production so that they could be connected to each other with Lindapter Hollo-Bolts during on-site assembly. Hollo-Bolt was specified for its high strength capacity and ability to be installed from one side of the Structural Hollow Section (SHS). To meet the required standards, manufacturing took place under the supervision of inspectors, including inspectors from the City of Seattle.

Each module was then wrapped in a protective air and water barrier, pressurised to keep windows in place and shipped on a private vessel from Europe, unloading at the Port of Everett in Seattle ready to be assembled. Mortenson Construction were the appointed main contractor for the construction of this seven-storey, 264-room hotel. Each 18,144kg modular unit was lifted by crane and carefully stacked on top of each other. Hexagonal head and countersunk Hollo-Bolts were then used to connect through the structural shear plates to the SHS of each module. Installation was quick and easy. Each bolt was inserted into pre-drilled holes and tightened with a calibrated torque wrench to the recommended tightening torque to provide the necessary clamping force. Hollo-Bolts

provided a weld-free connection that was quick and easy to install without damaging the waterproof membranes. This allowed the client to improve their modular construction method, which provided many advantages over traditional methods, including shorter constructions schedules, consistent quality control and reduced disruption on-site. The project team included Mortenson Construction, Gensler, Arup and Polcom. “It’s about 4 months faster to do modular versus conventional,” said Mortenson Construction Project Manager Lauren Bodeker. “What would typically take about 17 months on a more traditional hotel, can be done in about 13 months when building modular.” Source: www.lindapter.com

LEADING INDUSTRY CHANGE

At NHBC we believe more needs to be done to support the industry in trying to reach the Government’s aim to build 300,000 new homes a year by mid-2020s, says Richard Lankshear, Innovation Manager at NHBC. Offsite construction continues to be firmly in the spotlight, with the Ministry of Housing, Communities and Local Government (MHCLG) recently warning Government that an over-reliance on traditional building methods will see the UK fall far short of its target to deliver thousands of new homes. We are continuing to see a much greater interest in offsite systems. Last year saw a record number of systems submitted for review and this is now starting to be reflected onsite. Though the volumes are relatively small, developers are using closed panel systems and onsite innovations in greater numbers as well as piloting some homes built of volumetric units.

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This growing interest is also seen in the investment by housebuilders and housing associations in their own offsite production and the emergence of new, sizeable, manufacturers of offsite systems. The Government’s Housing White Paper and the Mark Farmer’s ‘Modernise or Die’ set out the opportunities for greater use of offsite methods and the industry is certainly responding. The 2018 NHBC Foundation report ‘MMC: Who’s doing what’, identified ‘quality’ as the primary driver towards the use of offsite. This potential raising of standards is welcomed by NHBC, though it should not be taken for granted. What is clear from our review of multiple offsite systems is

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

that quality is only achieved through investment – investment in design, in manufacturing procedures, in training and in construction. For more information visit: www.nhbc.co.uk/mmchub

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Modern Methods of Construction We work with industry to help deliver long-lasting quality homes. n From component materials and design, to onsite installation and connection n System appraisal and acceptance n Inspection of the whole building to NHBC Standards n Backed by NHBC Buildmark warranty and insurance

Talk to us... Call us now on 0344 633 1000 Email techservices@nhbc.co.uk or visit www.nhbc.co.uk/mmchub NHBC is authorised by the Prudential Regulation Authority and regulated by the Financial Conduct Authority and the Prudential Regulation Authority. NHBC is registered in England & Wales under company number 00320784. NHBC’s registered address is NHBC House, Davy Avenue, Knowlhill, Milton Keynes, Bucks MK5 8FP.

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INDUSTRY NEWS Metal Box Factory Revamped

Precast Manufacturer Reveals Secrets

A leading manufacturer is revealing its ‘secrets’ to help ensure businesses in the construction sector benefit from the best possible service. Elite Precast Concrete has become one of the UK’s biggest suppliers of construction products by combining best value with the highest levels of customer care.

The iconic Metal Box factory in Neath, an important part of the local economy for more than 80 years, is now operational again for the first time in almost four years. Local councillors were given a tour of the site to mark the occasion and be shown plans for the further development of the site. The factory is up and running again thanks to investment by Sevenoaks Modular, a Neath-based specialist in timber frame construction. The company aims to invest some £6.5million in acquiring and regenerating a large part of the industrial site. With phase 1 investment of almost £500,000 now complete, some 20 people are already employed at the site. Councillors for Neath Port Talbot, Sandra and John Miller were recently shown around the 250,000sq ft site and discussed the company’s future plans for it. Sevenoaks Modular, which currently employs around 100 people in Neath, anticipates it will double its workforce in the next 12 months in conjunction with its expansion to the site. The move will also allow it to go from producing 1,000 homes per year to more than 3,000 per year. John and Sandra Miller said: “When the Metal Box closed I don’t think anyone expected to see its doors open again. After our guided tour of the facility this morning it is easy to become hopeful again. This is an exciting development which highlights a company who are able to adapt and utilise the space available to them.

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Charlotte Hale, Director of Sevenoaks Modular added: “This is just the start for us. We will eventually have all our manufacturing based at the site. Our long-term plans will mean a significant investment in the local economy and allow us to keep pace with demand and all while pushing an environmentally friendly agenda, both in terms of the style of construction we champion and in terms of how we will regenerate the site itself.” In partnership with local education providers, it will also establish a training academy for young people looking to get a foothold in the construction industry, and open parts of the site up to use by the wider community. The company anticipates all the work will be completed and the site fully operational within 12 months. Sevenoaks Modular has an order book in excess of £10million all with tier one contractors and large property developers. It anticipates further rapid growth, which is partly being driven by government initiatives to build more homes quickly. The UK Government set a target of building 300,000 new homes in 2017 and the Welsh Government aims to build 20,000 new affordable homes by 2021. JG Hale Construction now has a turnover in excess of £40million. It will move all of its operations to the new site using the vast space as an indoor, offsite construction hub. Source: www.somodular.co.uk

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Now it has produced a ‘20 Questions’-style guide that sheds light on how the business operates, why it’s very different to other manufacturers and how it can claim to be both ‘the cheapest and the best’. The ‘Why Choose Us’ document is the latest addition to a growing online resource library which offers, entirely free of charge, a wide selection of useful safety and technical documents relating to the industry as a whole. Available via its website it reveals information about the background of the business, the benefits of its wide-ranging products, typical lead times and details of its approach to customer service. There are also facts about the company’s guarantees and accreditations, its commitment to health, safety and sustainability and its delivery service. Owen Batham, Sales and Marketing Director of Elite Precast (pictured), said: “We’ve grown quickly as a business and one of the biggest reasons for that is because we’re very different to traditional manufacturers. We focus on providing unrivalled levels of customer service – but we’re also the best price option every time. It’s by no means a typical approach for a manufacturing business, but it’s a dynamic and innovative method that very much sets us apart. So I thought it would be a good idea to produce a document that explains how we work and, most importantly, the benefits of that to our customers. “We have a lot of general technical information on our website, a large part of it for consulting engineers looking into specification for particular projects. A lot of manufacturers seem reluctant to publish these type of details, but we’re entirely open and transparent. Anyone can read the documents, copy them, download them, whatever they want – there’s no intellectual property rights because we have no secrets.” The resource library provides the kind of general information, advice and guidance vital to any business looking into precast concrete products. Source: www.eliteprecast.co.uk


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TENMAT has won the prestigious Queen’s Award for Enterprise for Innovation with its range of high-performance wall-cavity ventilated fire barriers.

1 TENMAT are proud to have won the 2019 Queen’s Award following the development of the latest range of ventilated fire barriers. It was the product’s unrivalled fire performance in numerous construction types, often outperforming Building Regulation requirements, which caught the eye of the Award judges. In addition, the product utilising ‘low smoke and zero

Fire Stopping in External Cavities

halogen’ intumescent material added to the products ‘life-critical’ credentials making it the safest product of its type, protecting buildings and their occupants.

problems facing our customers and the sectors in which they operate. We are particularly pleased to receive this award for an innovative solution which can be applied to improve building safety, not just in the UK but around the world.” For more information about TENMAT products visit: www.tenmat.com email: info@tenmat.com or Tel: 0161 8722181 Images: 01. The product utilises ‘low smoke and zero halogen’ intumescent material

Gordon MacLeman, Managing Director of TENMAT stated: “As an advanced materials company we look to provide solutions to the most pressing

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INDUSTRY NEWS Bathroom Pods for UK’s First Vineyard Hotel

Formal Negotiations Open on Sector Deal

The government has launched negotiations with the property industry to agree a formal deal with the sector that aims to boost housing delivery and quality including the use of offsite methods. In a letter to Bill Hughes, Built Environment Sector Deal Champion and Head of Real Assets at Legal and General, Housing Minister Kit Malthouse and Business Minister Andrew Stephenson said the government is opening formal negotiations with the sector.

Offsite Solutions has provided high specification bathrooms for the first vineyard in the UK to open a dedicated hotel. Llanerch Vineyard Hotel is located in the Vale of Glamorgan near Cardiff and offers five-star accommodation and a gateway to tourism in Wales. The stylish rooms enjoy stunning views across the Welsh countryside. Across Europe wine hotels are increasingly popular – this new development brings that experience to South Wales. The hotel owners specified two pod designs from Offsite Solutions’ extensive library of bathroom solutions. This significantly reduced design time and facilitated production. The bathroom pods for the luxury suites featured a granite counter top and shelf with underside LED lighting, a large picture frame demisting mirror with halo lighting, bath with granite surround, semi-recessed vanity basin, wall-mounted toilet, separate cubicle with overhead rainfall and hand-held showers, granite floor tiles and contemporary push button controls to the shower and bath for ease of use. The bathrooms for the superior double bedrooms have large format grey porcelain tiles, a wall-mounted basin with granite shelf, LED lighting, and a bath with overhead rainfall and hand-held thermostatic showers.

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The hotel was constructed using timber frame. This was engineered to create a recess in the cassette floor for the installation of the bathroom pods, allowing the application of factory-built bathrooms to work effectively within a timber frame, whilst ensuring level access floors. The application of bathroom pods in timber-framed buildings has created new markets for pod technology which includes housebuilding. Commenting on the project, Ryan Davies, Director of Llanerch Vineyard Hotel, said: “We wanted a high standard of aesthetics for the new hotel bedrooms and suites which have been carefully designed to our exacting requirements. Pods were recommended to us as being faster on-site and good quality. We think the new bathrooms are just fantastic and exceptional quality. They are low maintenance and installation was very straightforward with no trades on-site and simple connections for plumbing and electrics. The Offsite Solutions team was flexible, open, helpful and organised throughout in their approach to working with us. This really was a great experience from start to finish.” Source: www.offsitesolutions.com/hotels

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“As part of the Industrial Strategy we are striking a series of sector deals. These are partnerships between the government and industry on sector-specific issues and can create significant opportunities to boost productivity, employment, innovation and skills. Following a process of early engagement, we are now entering into formal negotiations on a built environment sector deal. While these negotiations will shape the final content of any deal, we expect it to meet overarching government objectives of: • Delivering more homes and improving housing quality for example through initiatives that support offsite construction • Improving the sector’s productivity through improved access to data and the promotion of PropTech • Enabling the sector to diversify its workforce through dedicated skills and employment strategies, as well as diversifying its firm base and increasing competitiveness • Promoting clean growth and supporting the sector’s transition to low carbon. The built environment sector deal will bring together investors, developers, real estate and asset management, architecture firms, PropTech firms and others upstream in the supply chain. By focusing on these organisations, the built environment sector deal will enable the implementation and delivery of the construction sector deal”. Source: www.gov.uk


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INDUSTRY NEWS Offsite Must Be Considered to Hit Housing Targets

The Housing, Communities and Local Government Committee has warned the Government that an overreliance on traditional building methods will see the UK fall far short of its target to build 300,000 new homes a year by mid-2020s. In a report published in July, the Committee urges the Government to unlock the potential for offsite to build homes quicker, more cheaply, while maintaining build quality. However, they will need to act quickly to increase capacity and improve investor confidence if it is to have a meaningful impact on UK housebuilding targets. At present, use of offsite in housebuilding is low and the Government will need to act quickly if it is to make an impact in meeting house building targets. Supply chain capacity will need to be increased, and greater focus placed on ensuring the workforce has the required skillset for developing technologies. The Government should work with Homes England and training centres, such as the Advanced Manufacturing Research Centre (AMRC), to develop targeted programmes targeted for use in the manufacture of offsite homes. Initial work to develop centres of excellence, bringing together businesses and academia to support innovation, is welcome but could be strengthened by coordinating with the Transforming Construction Programme and Construction Innovation Hub. These networks could form an ideal arena for testing and standardisation of offsite processes and components, as well as ensuring they comply with building regulations.

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The Government will also need to improve data collection and sharing if it is to overcome reluctance to utilise offsite among lenders, insurers and home buyers. To gain the confidence of the industry as a whole, as well as consumers, they must establish a database of MMC homes to demonstrate the long-term value and durability of offsite The Committee backs the creation of an ‘MMC Scheme’, setting out a single set of standards for warranty providers, to provide greater certainty.

“First and foremost they must create the conditions to improve investor and consumer confidence. Reluctance is understandable. The perception is that the building innovations of the sixties created homes that failed to survive half a century, while rows of Victorian terraces are still standing. Proving quality and longevity will be key. That is why we have called on the Government to collect and publish the data that prove new building methods work, and also show if they have failed.

Expansion of offsite faces many additional challenges including difficulties accessing land to build on, opaque and confusing building regulations and high upfront costs. The Government should investigate the specific impact of the current regulatory systems and access to funding on offsite, and consider options for measures designed to overcome existing barriers.

“The Government will also need to support the industry to grow the capacity needed for MMC to play a greater role in national housebuilding. They will need to ensure that the right training schemes and apprenticeships are in place so that we have the skilled workforce that can utilise MMC techniques. They must also work with the industry to support the development of robust supply chains and support innovative businesses develop. The housing system is in urgent need of a major boost and if the Government is to have any chance of meeting its ambitious target it must grasp every opportunity new technologies allow. But they must act fast and act now.”

Chair of the Housing, Communities and Local Government Committee, Clive Betts MP said: “If the Government is to have any chance of meeting its target of 300,000 new homes a year it cannot simply rely on traditional methods of construction. They must make a serious effort to support the use of new and emerging technologies that have the potential to have a transformative impact on the speed, cost and quality of home building. This is not simply about shifting production away from the building site and into factories. It is about seizing opportunities that modern technologies allow, whether it be precision manufacturing, use of new materials or digital working.

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

To download the full report and read the main recommendation and conclusions in detail visit the Parliament website at: https://bit.ly/2JjvfD2 Image courtesy: McAvoy Group Source: www.parliament.uk


The Institution of Civil Engineers Law and Contract Management Course 2019/20 DWF is the accredited provider for the Institution of Civil Engineers LCM exams in London. This course is made up of 10 evening sessions, being held on the 31st Floor of our

20 Fenchurch Street offices. The course will commence in late October 2019 and run until May 2020, with exams in June 2020. It will takes place on Tuesday evenings from 18:30 – 20:30. It is made up of 10 interactive evening seminars covering Module 2 (NEC3/4). Get in touch with our course leader, David, to find out more.

Course content: — — — — —

David McNeice Senior Associate

— — — —

M +44 7724 700438 E david.mcneice@dwf.law

— —

NEC4 Introduction Procurement and Choosing the right form of Contract Main and Secondary Options Understanding Scope (Works Information) Roles and Responsibilities under the NEC3/4 Time and Programming Payment Quality Assurance Compensation Events and Early Warnings Risk and Insurances Dispute Resolution

Beyond borders, sectors & expectations

www.dwf.law

We provide our customers a complete package, not only do we design, manufacture and deliver the timberframe structure, but we also supply the windows, external doors, internal door sets,stairs, architrave, skirtings, finishings insulation, plasterboard and a whole lot more. Scotframe Offices Sales and Manufacturing

Inverurie Tel: 01467 624440 Cumbernauld Tel: 01236 861200

www.scotframe.co.uk

Regional Sales Offices

Inverness Tel: 01463 717328 Dundee Tel: 01382 561772 Swindon Tel: 01793 234503 Manchester Tel: 0161 667 0225


SEISMIC CONSORTIUM

TRANSFORMING CONSTRUCTION THROUGH COLLABORATION & INNOVATION

The results of the Seismic Consortium have been unveiled and have been hailed as a trailblazer for transforming construction. Richard Crosby, Director of construction consultants blacc, describes how this pioneering consortium could transform the way schools are designed, procured and built offsite.

1 Seismic was established to carry out extensive research and development into the increased use of standardisation to drive down costs, reduce lead times and radically improve productivity in the delivery of outstanding primary schools. Two key innovations have now been launched – an innovative open source app for the design of primary schools and a universal connection solution and standardised structural frame for schools built offsite. The project was funded by UKRI through the Industrial Strategy Challenge Fund and Innovate UK and all the partners involved in the Seismic

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project, recognised its potential and each invested significant resources to ensure its success. • The original concept was developed by blacc who also provided project leadership expertise •

The McAvoy Group and Elliott collaborated to standardise the structural components, with a view to expanding the market and de-risking offsite for clients. These partners worked very well together, successfully combining their offsite manufacturing expertise for the success of the project

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

• The Manufacturing Technology Centre (MTC) co-ordinated the bid submission and acted as the catalyst to create the consortium. The MTC also gave the partners the opportunity to think beyond how schools have been delivered previously and apply more manufacturing principles to the construction of new schools, helping to develop more efficient processes. •

Bryden Wood provided digital expertise and led the development of the technology for the configurator.


SEISMIC CONSORTIUM

The starting point with the framing solution was to engineer a single, standardised way for The McAvoy Group and Elliott to interconnect their respective modular building systems. An engineered solution has been developed to connect each of the steel frames that make up a module – and to interconnect each module vertically and horizontally. The result is fewer welded joints and fewer connections – which in turn means less steel, less weight, faster assembly and therefore reduced cost. The frame solution has been standardised around the building clusters developed by the Department for Education (DfE). It has a single width and height, and three length options to suit school buildings – using the same engineered connection solution. The principle of standardised, manufactured components is that greater volumes will drive down costs and simplify procurement. For example, the DfE can pre-order a series of modules from any manufacturer that will be available ‘off the shelf’ for faster building assembly when a site receives planning. By rationalising the design of the steel frame, the number of components has been reduced. This means faster module assembly in the factory – increasing productivity by up to 50%. Work on site to interconnect modules is also more efficient. Research has shown that the new solution significantly reduces the number of frame components and will therefore use 25% less steel. The reductions in steel components and assembly time combine to generate a cost saving for these elements of up to 25%. With fewer components, the weight of the modules will reduce by 25% with no compromise on structural rigidity – resulting in 25% lower carbon emissions for the offsite construction

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of an average 40-module school. This is equivalent to over 155,000 miles of car driving or 17 flights from London to Sydney.

more efficient, sustainable and affordable buildings. We are in no doubt that these innovations have the potential to change the way primary school projects are designed, procured and constructed, helping to meet the rising demand for school places and increase capacity in the construction industry.

The Seismic School Configurator An innovative open source app has been developed which enables the full spectrum of community to get involved in the design of primary schools. The Seismic School app is a user-friendly, free web-based tool that has been developed to accelerate the initial design and feasibility stages for new primary schools. It will enable anyone from architects, planners, manufacturers to teaching professionals, school governors, parents and even pupils to configure a primary school building that will precisely meet their user needs on a specific site in full compliance with DfE and all regulatory requirements. The tool will significantly reduce the time and cost of the initial feasibility and design phases from weeks to minutes and will democratise the input of stakeholders by including them in the process. “The Seismic project is a powerful example that the targets set out in the Construction 2025 Strategy are achievable,” says Sam Stacey, Challenge Director – Transforming Construction at UKRI. “It is one of the first Innovate UK projects under Transforming Construction to be completed and demonstrates that this level of collaboration is the future of construction. “This initiative has been a tremendous success and I am delighted to report that it has hit all of the targets for Transforming Construction. The project partners have demonstrated an unprecedented level of collaboration which we hope will inspire other forward-thinking projects to help innovate in construction and produce

“The commitment, investment and R&D capabilities of each of the project partners has been very impressive. Seismic has shown how by working together as an industry, even greater progress and innovation can be accomplished.” The benefits are already being realised in new DfE procurement frameworks. The team is in the process of completing testing of the frame solution. The next stage is collaboration with steel fabricators to develop the standardised components and establish a supply chain with a view to making these available to the offsite market in the coming months. This approach will aggregate demand to reduce cost. The aim is to develop a ‘product family’ for different types of buildings, such as residential. The team also has aspirations to ‘componentise’ other parts of a school building to be able to offer a whole school solution, including walls and roofs. For more information and to access the Seismic School app visit: www.seismic-school-app.io Images: 01-02. The Seismic Consortium’s key innovations are an innovative open source app for the design of primary schools and a universal connection solution and standardised structural frame for schools built offsite. 03. Lauren Allen, Project Manager at the Manufacturing Technology Centre with David Clark, Manufacturing Director of The McAvoy Group at the Seismic launch.

JULY/AUGUST 2019 | WWW.OFFSITEMAGAZINE.CO.UK

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OFFSITE EXPO THE CATALYST FOR CHANGE

From Rethinking Construction (1998) to the acclaimed Modernise or Die report, the need to improve the construction industry has been well documented for many years. The political landscape is changing, spurred on by climate change, the housing crisis and the urgent need to increase productivity.

Image courtesy: Vision Modular Systems

These compelling factors have resulted in the launch of OFFSITE EXPO, taking place at the Ricoh Arena, Coventry on 24 and 25 September 2019. OFFSITE EXPO is the brainchild of leading industry experts who understand the vital requirement for a dedicated event that will act as a catalyst for change and drive this growing momentum forward.

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Those who are challenging traditional practices from across the globe will stand alongside our home-grown talent to demonstrate what can be achieved with a progressive approach. Construction is at a critical crossroads, and it is clear that contractors need to adapt to become more like the innovative disruptors in other manufacturing sectors, such as aerospace and automotive.

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

OFFSITE EXPO brings together the sector’s most influential organisations, individuals, commentators and business leaders who are instrumental in industry progression. The event will play host to inspiring UK and international offsite manufacturers, component suppliers and digital innovators, showcasing a broad spectrum of offsite systems and smart technologies.


EXPERIENCE

SUMMIT

THE CPD ACCREDITED OFFSITE MASTERCLASSES

Free CPD-accredited Masterclasses will be presented by the industry pioneers who are making the headlines, such as Waugh Thistleton Architects and Stewart Milne Timber Systems, who have supported the likes of Barratt Homes in their offsite journey. These Masterclasses will focus on key industry innovations and provide a comprehensive and balanced perspective on rapidly emerging sectors. The Masterclasses are split into offsite and digital technologies, including Precast Concrete, Digital Construction, MEP & Pod, Light Gauge Steel Frame, Skills & Innovation, Hybrid, Structural Timber, Training & Skills, Volumetric Modular and Roofing. Attending CPDs has become a vital part of research and career development for many construction professionals. In particular, many industry institutes/bodies now require members to undertake a minimum number of CPD hours each year. With circa 20 hours of informative CPD accredited content, the OFFSITE EXPO Masterclasses provide the opportunity to learn directly from those who are shaping the future of construction and help fulfil this commitment.

EXPLORE

SMART TECHNOLOGIES

OFFSITE EXPO will feature the smart technologies that are changing the face of construction, with a range of devices making complicated tasks much easier – from Virtual Reality to smart helmets and digital software efficiencies. The rate of technological advancements is accelerating at such a relentless pace, it cannot be ignored. The combination of offsite manufacturing and digital construction technologies present a compelling proposition. Virtual Reality has transformed the way that architects present their visions. It immerses the user by making them feel like they are experiencing the simulated reality first-hand – allowing clients to play an integral part of the design process and ‘virtually’ enter the building and validate the layout. Augmented Reality, on the other hand, provides more freedom for the user because it does not need to be a head-mounted display. Augmented Reality takes the real world and adds something to it – for example, a new extension could be digitally superimposed onto an existing building. With over 100 exhibitors, features and offsite technology showcases, OFFSITE EXPO will provide the opportunity to interact directly with smart technology suppliers and full-scale feature builds. Housebuilders, developers, architects, engineers, specifiers, contractors and housing clients will be able to view the widest display of new and innovative offsite solutions within the built environment and interact with an extensive range of offsite technologies.

EXPECT

INTERNATIONAL INNOVATION AT THE OFFSITE SUMMIT

With sessions chaired by some of the industry’s biggest names, including Mark Farmer, author of the Modernise or Die report, over 30 international speakers ranging from architects and specifiers to engineers, manufacturers and project managers, will participate in the Offsite Summit. Delegates will have the chance to interact with speakers during panel Q&A sessions, structured networking and an evening drinks reception. Advanced offsite approaches and smart technologies are changing the face of construction globally, and we can learn from the way that other countries are addressing similar challenges.

REGISTER FOR YOUR FREE VISITOR PASS OFFSITE EXPO will feature a combination of advanced offsite manufacturing approaches and smart digital construction technologies that are transforming the way buildings are designed and constructed. This exhibition and conference will provide the ideal forum for people to engage with key industry contacts, network in vibrant surroundings and acquire new offsite industry intelligence. To book your FREE place at this event, go to: www.offsite-expo.co.uk/book

JULY/AUGUST 2019 | WWW.OFFSITEMAGAZINE.CO.UK

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At the heart of Offsite Expo, the Offsite Connect Buyers and Specifiers Forum provides a structured, effective way to meet with new and existing offsite industry manufacturers and suppliers who are exhibiting at the event. RS YE S D U R 0 B FIE RE 10 ECI ISTE ER SP EG OV ND Y R A AD RE AL

EXCLUSIVE VIP BENEFITS OF OFFSITE CONNECT • A dedicated Offsite Buyers and Specifiers team who are responsible for looking after your needs • An invitation to the exhibitor networking party

We know that your time is at a premium and that you don’t have enough time to meet new contacts. As a result, you may be missing out on engaging key people who could have a huge impact on the future success of your business in terms of offsite technology. Architects, engineers, buyers and specifiers are invited to join the Offsite Connect Forum, which provides a solution to address offsite construction/technology project needs by facilitating personally selected ‘oneto-one’ business meetings. The Forum will provide an opportunity to network with key offsite industry experts who have a genuine desire to conduct

purposeful meetings. It will also be a chance to learn about the latest offsite product innovations. This focused approach has proved to be highly successful in creating new business relationships.

WHO COULD YOU MEET AT OFFSITE CONNECT? As an offsite buyer, you will have VIP access to Offsite Expo. With hundreds of leading companies participating in our inaugural event as exhibitors and event contributors, you can exploit the best business opportunities from the Offsite Expo suppliers and manufacturers in one location.

• A private networking area to host your meetings The Offsite Connect Buyers and Specifiers Forum provides a unique opportunity for your company to address your offsite construction project needs by facilitating ‘oneto-one’ business meetings with the companies YOU want to meet. The forum website allows you to create your own bespoke programme of handpicked supplier meetings, which, when coupled with relevant seminars over the two days, will help you to fulfil your immediate to long-term project needs.

Register online at: www.offsite-connect.co.uk

Only exhibitors and sponsors participating in OFFSITE EXPO can access the OFFSITE CONNECT BUYERS AND SPECIFIERS FORUM - to exhibit or sponsor contact: Julie Williams - julie.williams@radar-communications.co.uk or call 01743 290042

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WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019


FFSITE

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SEMINAR THEATRE 1

DAY ONE 24.09.2019

OFFSITE MASTERCLASS HIGHLIGHTS

Sponsored by:

Speakers in the spotlight STRUCTURAL TIMBER SESSION Jeptha Schaffner - Project Manager & Engineer, Blumer-Lehmann With a background in carpentry and highly experienced in engineered timber, Jeptha now project manages timber projects, leading the Freeform team at Blumer-Lehmann AG. Case Study: Cambridge Mosque Discover the complex timber geometry that enhanced this £20-million mosque’s stunning architecture.

TRAINING & SKILLS SESSION Rohan Bush - Head of Public Partnerships and Future Workforce, Construction Scotland Innovation Centre Rohan holds degrees in architecture, building science and political studies. She has 18 years’ experience in the built environment sector, including managing building innovation funds in Melbourne and helping to establish the New Zealand Green Building Council. Are We Offsite Ready? Find out how you can overcome low productivity, lack of research, low investment in innovation and skills shortages in offsite manufacture.

VOLUMETRIC MODULAR SESSION Ben Drake - Associate Structural Engineer, Peter Dann Ben directs a skilled team of structural engineers who deliver high-end volumetric modular projects in the UK, Canada and the USA. Ben has extensive structural design experience working with complex buildings around the world, including those requiring seismic design. Optimising for Offsite – A Structural Engineer’s Perspective Learn why DfMA is essential for optimising design in manufacture during the earliest stages of planning.

HYBRID CONSTRUCTION SESSION Andy Goodwin - Managing Director, B&K Structures Adopting a hands-on approach, Andy has supported B&K Structures through the transition from a structural steelwork fabricator into the sustainable frame contractor they are today, supporting project teams through every stage of their construction journeys. Case Study: Orsman Road B&K Structures used a progressive approach to reduce environmental impact and ensure optimal build quality. Explore the sustainable hybrid engineered timber and steel structure for a widely recognised six-storey commercial building.

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SEMINAR THEATRE 2

DAY ONE 24.09.2019

OFFSITE MASTERCLASS HIGHLIGHTS Speakers in the spotlight PRECAST CONCRETE SESSION Colin Davis - Director, Studio Partington Colin manages the strategic management of business planning, finance and quality assurance. He was the lead director for Hox Park, a student housing scheme in Surrey with a precast concrete superstructure that has been shortlisted for renowned awards. A Precast Solution for Student Accommodation Learn about the aesthetic, cost, thermal and low-maintenance benefits of precast concrete and how these enhance student accommodation.

DIGITAL CONSTRUCTION SESSION Daniel Leech - Group CEO, Technical Design Services Group Daniel’s ambition to make the industry collaborative, upskilled for growth and sustainable for future generations through BIM practices has seen him become a recognised thought leader and board member of the BuildOffsite Governing Forum. Case Study: Hong Kong Airport – Investing in Digital Collaboration Explore the design ideas behind the complex steel brace connection that forms the new roof for Hong Kong’s Terminal 2.

MEP & POD SESSION Colin Goodwin - Technical Director, BSRIA Colin manages BSRIA technical input to regulatory, legislative and parliamentary activity, including energy policies and building regulations. He is a Fellow of the Chartered Institute of Building Services Engineers and Member of the American Society of Heating & Refrigeration Engineers. Chair As the technical director of industry partner BSRIA, Colin will be introducing thought leaders in the MEP and POD industry, who will be discussing M&E engineering and bathroom pod design, specification and procurement.

LIGHT GAUGE STEEL SESSION Peter Burchill - Business Development Manager, EOS Peter has played a central role in steelwork specification for 23 years, detailing and promoting light steel frame in award-nominated projects for residential, student accommodation and healthcare projects. Case Study: The RAM Quarter Follow EOS’ end-to-end steel framing systems journey as they transformed a brewery site into a residential community of shops, loft-style apartments and riverside walks.

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WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

Sponsored by:


All Explore Offsite Masterclasses at Offsite Expo are CPD Certification Services accredited and qualify for Continuing Professional Development points

OFFSITE MASTERCLASSES Speakers also include: DAY 1: 24.09.2019 - SEMINAR THEATRE 1

Andrew Carpenter Structural Timber Session Chair

Pete Blunt Case Study: Glasdir School

Simon Horn Case Study: St Wilfrid’s Walk Development

Ian Heptonstall Understanding the Skills Gap in Offsite Construction

Shaun Hunt Training in Modern Methods of Construction

Andy King Volumetric Modular Session Chair

James Talman Roofing Session Chair

David Padmore Lightweight Roofing In Modular/Offsite Buildings

Gavin White Hybrid Session Chair

Nigel Banks Case Study: Gateshead Innovation Village

Marcus Bennett Training & Skills Session Chair

All Masterclasses are FREE to attend – register online at www.offsite-expo.co.uk

DAY 1: 24.09.2019 - SEMINAR THEATRE 2

Elaine Toogood Precast Concrete Session Chair

Bernard Graham Offsite in Concrete Technology

Daniel Westgate Offsite Solutions for Multi-Storey Buildings

Steve Chesters Light Gauge Steel Session Speaker

Andrew Way Light Gauge Steel Session Chair

Joanne Booth Value Engineering of Light Gauge Steel Frame Systems

Alberto Jena Digital Construction Session Speaker

Ben Taunt Digital Construction Session Speaker

Stephen Wade-Palmer Best Practice in Bathroom Pod Design & Specificatio

Lewis Jones Early Engagement & Digital Design

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FFSITE

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SEMINAR THEATRE 1

DAY TWO 25.09.2019

OFFSITE MASTERCLASS HIGHLIGHTS Speakers in the spotlight STRUCTURAL TIMBER SESSION Frank Werling - Head of Technical Engineering and Design, Metsa Wood Frank designs, drafts and schedules turn-key industrial steel units for award-winning projects. Frank is the brains behind the certification of Metsa Wood’s engineered wood products, software development and engineering tools. Case Study: Elveden Forest – Center Parcs Discover how timber frame can be used to construct architecturally inspiring woodland lodges that blend naturally into tranquil forest surroundings.

DIGITAL CONSTRUCTION SESSION David Clark - Manufacturing Director, The McAvoy Group David leads the Group’s pioneering work in applying digital transformation to offsite construction. His use of BIM, digital scanning, virtual reality and tablets to collect data have enhanced customer engagement and won McAvoy the BIM Contractor of the Year award. Understanding the Importance of Digital Construction in Offsite Manufacturing Learn how to implement digital offsite technology to lower costs, emissions, hazards and disruption in your projects while improving speed of delivery and exports.

VOLUMETRIC MODULAR SESSION Nick Griffin - General Manager, Portakabin Nick leads a highly experienced team of volumetric specialists in their bid to transform systems for the manufacture of modular buildings that challenge traditional perceptions of volumetric modular construction. Case Study: Royal Stoke University Hospital Explore the volumetric and modular technology that enabled the build of an in-demand 64-bed hospital ward in under four months.

VOLUMETRIC MODULAR SESSION Patrick Hayes - Head of Structures & Offsite Construction, Meinhardt UK With extensive experience in the design of basements, complex analysis, long-span transfer structures and stability systems, Patrick engineers structures for mixed-use schools, universities, laboratories, commercial buildings, residential accommodation and hotels, as well as bridges and steel infrastructure. Case Study: Essential Living Greenwich Scheme Find out how early engagement with modular suppliers in the building design process maximises the benefit of modular integration.

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WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

Sponsored by:


All Explore Offsite Masterclasses at Offsite Expo are CPD Certification Services accredited and qualify for Continuing Professional Development points

SEMINAR THEATRE 2

DAY TWO 25.09.2019

OFFSITE MASTERCLASS HIGHLIGHTS

Sponsored by:

Speakers in the spotlight PRECAST CONCRETE SESSION Alan Clucas - Director, Laing O’Rourke Following over 35 years’ experience in designing pre-cast concrete and structural steel components for car parks, offices, retail, roads, bridges, tunnel segments, railway sleepers, nuclear containment, prisons and high-volume standard product applications, Alan now offers offsite consultancy services. A New Model for Construction Explore the Laing O’Rourke operating model and manufacturing strategy for improving construction practices.

LIGHT GAUGE STEEL SESSION Robert Clark - Head of Business Development, Fusion Having worked in the light gauge steel industry for 20 years, Robert undertook the initial research and development that led to the Fusion system. Now, as head of business development, Robert plays a central role in mapping Fusion’s future. Fusion and the Golden Thread Find out how the construction sector can transform inefficient project-led approaches to drive the products and technology that make schemes successful.

SKILLS & INNOVATION SESSION Marcus Bennett - Future Skills and Innovation Lead, CITB Marcus is experienced in offsite, immersive and virtual reality for learning and digitalisation. He has led a programme of research quantifying the demands, risks and training provision for construction occupations to inform skills plans across the UK. Faster, Smarter, More Efficient: CITB & Construction’s Future Skills Discover which industry skill gaps need to be filled and what construction opportunities are available to utilise these.

HYBRID CONSTRUCTION SESSION Ed Whitehead - Senior Architect, Waugh Thistleton Architects Ed believes that high-quality social and affordable housing form the bedrock of a fair and vibrant society. He has worked on a variety of housing projects at all stages of design development and is responsible for the planning and implementation of quality management systems. Case Study: 106 Lewes Road Learn how lightweight prefabricated timber and CLT can be used to construct quality student housing in under a year.

JULY/AUGUST 2019 | WWW.OFFSITEMAGAZINE.CO.UK

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FFSITE

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DAY TWO 25.09.2019

OFFSITE MASTERCLASSES Speakers also include: DAY 2: 25.09.2019 - SEMINAR THEATRE 1

Rupert Scott Structural Timber Session Chair

Byron Starnes Design to Fabrication Workflow for the Built Environment

Kevin Jones Volumetric Modular Session Chair

Andy King Case Study: Specific’s Active Office

John Eynon Digital Construction Session Chair

Tom Lench BIM & Metframe

Stuart Scott Goldsmith Street Passivhaus and 2D Primary Structural Systems for Mainstream Housing

All Masterclasses are FREE to attend – register online at www.offsite-expo.co.uk

DAY 2: 25.09.2019 - SEMINAR THEATRE 2

Jenny Burridge Precast Concrete Session Chair

Xavier Van der Wee Insulated Twin Walls – Technique & Applications

Simon Harold Case Study: Kingston University

Darren Richards Light Gauge Steel Session Chair

Phil Jasper Case Study: Blenheim Point Student Accommodation

Alison Nicholl Skills and Innovation Session Chair

Trudi Sully The Construction Innovation Hub

Tim Snelson Hybrid Session Chair

Nicola Carniato Luke Boorman Hybrid Structures Office Enabling the offsite & Residential Markets workforce of the future

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David Ellison Case Study: Godiva Place Student Accommodation

Andrew Shepherd MMC – Construction Disruption

All Masterclasses are FREE to attend – register online at www.offsite-expo.co.uk

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019


Focusing on International Offsite best practice the Offsite Summit is co-located with OFFSITE EXPO and is FREE to attend.

SUMMIT PROGRAMME

Day One - 24.09.19 UNITED KINGDOM

CHAIR: Mark Farmer – Chief Executive, Cast

Alex Goodfellow – Group Managing Director, Stewart Milne Timber Systems & Oliver Novakovic – Technical and Innovation Director, Barratt Developments AIMCH Principles and the link to SMTS Offsite Investments. Rory Bergin – Partner, Sustainable Futures, HTA Design & Michael Hough – Director, MJH Structural Engineers The Tallest Modular Tower in the World – 101 George Street, Croydon

UNITED STATES

CHAIR: Mark Farmer – Chief Executive, Cast

Gerard McCaughey – CEO and Chairman, Entekra The Second American Revolution: Transforming US Homebuilding with Offsite Henry Mickleburgh – Executive VP, Skystone Group LLC An Overview of Skystone’s Marriott AC NoMAD on 6th Avenue, Manhattan.

SINGAPORE

CHAIR: Phil Wilbraham – Programme Director, Heathrow

Dr Rose Nguan – Director, Building and Construction Authority Singapore Construction Productivity Policies and Strategies Frven Lim – Director, DP Architects The Important Role that Biophilia Plays Across a Wide Spectrum Ranging from Health and Well-being to Livelihoods and Economy

AUSTRALIA

CHAIR: Warren McGregor – Chief Executive, PrefabAUS

Warren McGregor – Chief Executive, PrefabUS An Australian Insight: Analysing the Benefits of Offsite Construction Neil Wypior – General Manager, Eurofast Prefabrication Prefabrication in Building Services – Impacts and Opportunities

Day Two - 25.09.19 EUROPE Angel Fernandez – Director of Offsite, AEDAS Homes Why Offsite Construction is Now Taking Off in Spain and the Role of AEDAS Homes as One of Spain’s Leading Housebuilders Martin Joos – Managing Director, RENGGLI International Case Studies on a Variety of Offsite Timber Construction Projects Throughout Europe Pascal Chazal – CEO, Hors Site How Construction is Using the Planet’s Resources

JULY/AUGUST 2019 | WWW.OFFSITEMAGAZINE.CO.UK

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CITB

IMPROVING SKILLS FOR HOUSING DELIVERY

The recent news that the Construction Industry Training Board (CITB) is pumping £1.2million into offsite construction teaching materials including those for ‘virtual or immersive environments’ follows its recent report into the ongoing skills crisis and long term implications for the offsite sector. categorisation of offsite developed by the MHCLG working group on ‘MMC’ assurance, insurance and mortgages, volumetric construction was defined as the production of 3D units in controlled factory conditions which are then assembled together onsite. Five different offsite scenarios were considered using different percentage bases for construction methods. For example – Scenario 1 – assumed that 50% of homes built in 2025-26 will be based on the mix of types currently being built and the other 50% being built with equal shares of panelised and volumetric types. Current levels of panelised and volumetric construction techniques used in homebuilding are estimated to be at relatively low levels – circa 6%. The five scenarios show that: “ramping up volumes of panelised and volumetric construction to just over 50% of total build might help mitigate some of the longer-term pressure on skilled trade and manual workers.” The analysis highlights that in the short term to 2021: “an increase in the number of homes being built is likely to result in an increased demand for a workforce that supports the existing mix of build types, unless there is a rapid increase in offsite adoption.”

1 Using analysis undertaken by Whole Life Consultants, the CITB report ‘The Impact of Modern Methods of Construction on Skills Requirements of Housing’, found that if housebuilding activity were to reach the levels currently being set by the government without any increase in the use of offsite methods, the construction industry would need to boost staff numbers by 195,000 over the next seven years.

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Commissioned by the Ministry of Housing, Communities and Local Government (MHCLG) it was set to better understand the contribution that increasing offsite methods in UK homebuilding could make to the workforce needed to deliver them. The study focused on the changes to the workforce profile for both panelised and volumetric homes in relation to those delivered by ‘traditional’ (brick and block). Using the definition and

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

The report picks out a series of challenges for the homebuilding sector including the need to grow and develop skilled trades and manual workers to support an increase in the number of homes built using current construction methods. One key challenge will include upskilling existing workers to cover ‘new’ disciplines such as site management, integration, onsite placement and assembly that are increasingly required for offsite manufacture. This in addition to developing the array of digital skills that are an ever-increasing part of construction work.


CITB levels of homebuilding, regardless of construction technique used, is likely to lead to an increased demand for technical, professional and officebased support roles of nearly 90,000 workers by 2025-26.”

2 While some workforce estimates focus only on the manual and skilled trades that tend to be constructionsite based, there is an almost equal requirement for non-site-based workers. “Our current estimate of the homebuilding workforce would be 266,000 site-based workers (manual and skilled trades) with nearly 227,000 non-site based, such as office staff, technicians and professionals such as architects and surveyors. The non-manual workforce requirement is consistent across the baseline and offsite scenarios and increasing

The report also outlines a range of recommendations for Government and the CITB in helping the industry respond and embrace the challenges of delivering the levels of homes that are needed – the much quoted – 300,000 per annum – using current construction methods, while also promoting and developing more offsite delivery. Key to progress is collaboration and includes linking into Government action “a forum that promotes and shares information, CITB may have a role in sharing details that form sector insight to support workforce development, by promoting homebuilding as a career within the construction sector by ensuring that there are training standards and qualifications that cover the full range of skills that homebuilding will require in the future and by helping employers to understand and access the range of training opportunities that they will need.” Likewise, there is also an opportunity for Government to help promote sharing information, such as real

data on workforce requirements and best practice information on offsite build techniques, which could help stimulate further industry adoption. This recognises that Government has a “dual role as client for homebuilding, along with an enabler of wider conditions for homebuilding such as planning policies and skills development.” The scale at which offsite methods need to be adopted is massive and is possibly the main challenge for homebuilding, but as the report picks out, “overall there is potential for increased uptake of offsite to enable more homes to be built and productivity to be improved – the biggest impact would be if significant and rapid progress was made in the adoption of volumetric construction techniques.” To download and read a copy of the publication: The Impact of Modern Methods of Construction on Skills Requirements for Housing: a report on the skills implications for both panelised and volumetric housing construction, visit: www.citb.co.uk Images: 01-02. CITB Analysis into offsite construction and skills requirements

1938-2018

MPBA representing the industry for 80 years in the Offsite Sector. THE MODULAR & PORTABLE BUILDING ASSOCIATION The voice of the modular industry

MPBA are the representative body of the Volumetric and Modular building industry. Be part of it.

SOME MEMBERSHIP BENEFITS: • High quality learning and training • Industry wide marketing promotion • Access to the NEW Learning Hub

• FREE Guidance and support

on all health and safety issues

• FREE Technical Advice • FREE Employment law services • FREE Regular industry and legislative updates

Join here www.mpba.biz

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MODULAR DESIGN GUIDE

CHANGING HOUSING PERCEPTIONS

Swan Housing Association is leading the way on modular housing and recently launched their own Modular Design Guide based on their learning from launching their own volumetric modular housing factory. which opened its own offsite modular factory in 2017, has already delivered precision-engineered homes to its Beechwood development in Basildon, Essex, and is now manufacturing and delivering approximately six modules per week to its Watts Grove development in East London.

1 to them, particularly with secured development pipeline of over 8,000 homes, the majority of which are being built by their in-house developer, NU living including homes for private sale.

2 A housing association with a difference, Swan is focused on achieving the biggest social impact possible and creating balanced neighbourhoods by specialising in social, affordable and private sale homes. Swan’s focus is ensuring as many people as possible have ‘somewhere to feel at home’, which is why modular housing and the use of offsite manufacturing is of such interest

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Every penny of Swan’s profit is reinvested to create further funds to deliver more affordable housing, regenerate neighbourhoods in Essex and London and provide services to their residents. To date, £65million has been reinvested and by 2027 they aim to generate over £250million of profit to help them make the maximum impact on affordable home supply. Innovation is at the heart of Swan’s approach and they have invested over £3million into their state-of-theart factory in Basildon, Essex, where they use cross laminated timber (CLT) to build modular homes. Swan,

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Watts Grove will deliver 65 one, twoand three-bedroom shared ownership apartments in Bow, Tower Hamlets. Construction work began in early 2018 and it is expected that these homes, which were shortlisted in the Inside Housing Development Awards for ‘Best Approach to Modular’, will be the UK’s first mid-rise CLT modular homes. Watts Grove has been instrumental in the research and development of the modular guide. Based on Swan’s ‘NU build’ modular system, the guide aims to give the design teams of new homes an understanding of the interrelationship between the consultants, the client and the factory. Earlier this year, Swan, along with award winning architects Waugh Thistleton, launched their ‘Modular Design Guide’, setting out considerations for designing modular housing. The guide is not a pattern book, but instead provides the tools for the designer to develop their own unique project, whilst thinking about how each module is made, transported and assembled at every stage of the design development. “Swan is truly committed to delivering innovation,” says Geoff Pearce, Swan’s Executive Director of Regeneration and Development. “Having opened our own offsite modular factory in 2017, we are convinced that this method will enable us to deliver high-quality homes that people will want to live in, at the same time building local and national expertise in


MODULAR DESIGN GUIDE manufacturing and supporting the UK modular industry. This guide, we hope, will encourage others to consider modular, whilst enabling high-quality homes to be built, quicker, more sustainably and at a lower cost.” Working closely with Ramboll and Waugh Thistleton Architects – specialists in designing in engineered timber and offsite solutions, the Guide, which took two years to develop is hoped to encourage more designers, organisations and developers to look at the possibility of delivering homes via offsite manufacturing. “The NU build Guide is the culmination of two years of collaborative work with Swan developing their modular system,” says Andrew Waugh, Founding Partner, Waugh Thistleton Architects. “Speed of delivery, efficiency of production and waste reduction are at the heart of this book, demonstrating how the construction industry can modernise to meet the 21st century demands for quality as well as responding to the urgent climate emergency we face.” Paul Williamson, Managing Director of NU Build adds: “As the UK moves towards more factory built homes we wanted to provide a Guide which prompts the design team to ask the early questions that need to be asked, something which all teams within the process could look at for guidance.” So together with the use of LEAN processes, the latest cutting machine technology, BIM and a focus on standardisation of process not product, Swan are able to manufacture high quality, stylish new homes that buyers really want to live in. Swan is at the forefront of modular housing and it’s not afraid to share its success and knowledge with the industry. This year alone, Swan has welcomed over 500 guests to their factory including The Commons Select Committee on Housing, Communities and Local Government and the newly appointed Minister for Construction, Andrew Stephenson MP. In his first official visit as Minister, Mr Stephenson took a tour of the factory to learn more about Swan’s precision engineered modular housing, where he saw first-hand the scale of Swan’s operation, which recently moved into double shifts, employing over 60 local workers.

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4 “The use of offsite modular manufacturing is helping us harness new methods of working,” said Andrew Stephenson. “Delivering on the Government’s Construction Sector Deal to transform the sector’s productivity through innovative technologies and a more highly skilled workforce. The methods being deployed at Swan’s modular housing factory are a testament to the Government’s modern Industrial Strategy, creating a business environment equipped for the challenges and opportunities of new technologies and ways of doing business.” For 25 years Swan Housing’s commitment has remained the same – to deliver quality affordable homes

and create thriving communities, somewhere to call home, for those who need it most – today, tomorrow and for generations to come. For more information visit: www.nubuild.co.uk www.nuliving.co.uk www.swan.org.uk

Images: 01-02. The Modular Design Guide will encourage more designers, organisations and developers to look at the possibility of delivering homes via offsite manufacturing 03. Minister for Construction, Andrew Stephenson MP toured the Swan factory to learn more about the precision engineered modular approach 04. Watts Grove will deliver 65 shared ownership apartments in Tower Hamlets

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EOS ROUNDTABLE

NEW RULES TO DESIGN BY

EOS recently hosted one of our regular roundtable events – at the heart of the discussion was design for manufacture and assembly (DfMA), the growth of digital design and how these new tools are playing a huge part in the growth of offsite construction activity using the myriad offsite technology options now available.

In 2014 RIBA grabbed many headlines with its DfMA Overlay to the RIBA Plan of Work 2013. The publication represented a major step in offering advice and encouraging early engagement of contractors and manufacturers and makes it clear when offsite methods may be introduced and what the impact on the ‘traditional’ design process would be when using offsite techniques. Although launched to a minor blaze of publicity the debate on its benefits, and indeed its use, has not been sustained – has the industry really got to grips with it? The RIBA Overlay was initially developed for project teams to understand what offsite can do and inspire architects to think differently. But the feeling is that this is still not fully understood and the rules not being drilled into a new young

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generation of architects and building designers. Architects need to know about the variety of offsite solutions available so they can then recommend the right solution at the right time for the right client. With many competing offsite systems and materials on the marketplace, all architects and designers are faced with the issue of making these work together successfully. Interfaces and a myriad of components can cause confusion and poor building performance and once again brings into question the demand for an improved flow of offsite processes from the factory to the construction site where thorny – and expensive – concerns surrounding onsite installation can cancel out the plus points created within the manufacturing facility.

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RIBA recommends that the design process needs to start with an offsite solution in mind and the RIBA Overlay addresses this by adapting the standard Plan of Work and associated ‘RIBA Stages’. The use of offsite technology invariably means that the design process has to be completed in advance of the manufacturing being started. Also inherent is the strong argument that ‘early contractor involvement’ is the natural direction for offsite manufacturing. As Steve Thompson, Managing Director at EOS, says: “We need a collaborative approach from the beginning of the design with both contractors and subcontractors.” “In theory the Plan of Works Overlay covers all the bases but it has not been particularly well absorbed,” says Brendan Geraghty, Director


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EOS ROUNDTABLE

at architects Geraghty Taylor. “The Overlay is a really strong model of how the optimum process should work in a complete cradle to grave cycle. Everybody’s learning quite quickly about new offsite techniques and new offsite technologies. It is a process of educating the profession but it is also a process of educating clients on what can be done if the right ‘project culture’ is implemented at the start.” Often the more mundane but important parts of offsite construction and DfMA are overlooked including transport of modules and panels, final site shape and access plus the practicalities of how you get cranes in and out. These concerns can sometimes actually determine the shape of the building, number of storeys, the type of offsite technology that is feasible and all works towards efficient design. Through active engagement with these prosaic problems comes a certain amount of education and the DfMA philosophy helps to develop a ‘cultural mindset’ within which the project team can operate and develop. Standardisation & Early Engagement So early adoption is always key to the success of offsite manufacture. It is a recommended part of the RIBA Overlay and DfMA approach but the overall success is being driven – and hindered in equal amounts – by the need for ‘construction culture and engagement process change’. A disrupting influence is needed ‘somebody has to stick their neck out and say we’re going to do this’.

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Unusually, a disrupting influence has been government support for offsite via Homes England. A move that many major Tier 1 contractors are slowly coming around to by using more offsite methods, if only as a tool to improve levels of productivity – something the UK construction sector is constantly plagued by. “Our commitment to offsite underpins our programme to drive out waste from our sites, improve productivity and use new digital tools,” says Colin Westpfel, Head of Design, Balfour Beatty. “We are looking at every kind of opportunity whether it’s volumetric or steel frame and looking at it very closely. So that for me is a positive story.” For a wider and really successful expansion of offsite methods a broader swathe of the construction and client community need to get to grips with what it can deliver – not just the design community. Placing the emphasis solely on the ‘shoulders of architects is somewhat harsh and a wider set of people need to be brought in to advise clients’. There is a certain UK industry malaise in that ‘we are entrenched in previous years of construction, procurement and unfortunately some bad habits’. The use of DfMA is about taking steps to breaking some of those bad habits and to adopt a different cultural approach. Some of the bad habits are the refusal to see standardisation as something of benefit and not to be wary of. Standardisation brings many cost efficiencies but may not always deliver wide choices – so can

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the focus on greater standardisation create a potential ‘turn-off’? There is sometimes a perception from architectural and construction circles that standardisation is a bad thing. Certainly some architects are suspicious of standardisation and fear that it can stifle creativity and freedom of expression. For a manufacturer standardisation is the perfect scenario. “Some designers feel they are losing their grasp on architecture,” says Kelly Harrison, Associate, Heyne Tillett Steel. “And the streetscape would be ruined if everything was standardised. As an industry I think that’s definitely when we need to be proving them wrong and that there’s variability in the models, even in the standard complexities behind them. But they can look different and still get variety with the clever application of the ‘rules base’.” For many it is not the fear of standardisation but understanding what should get standardised. Being prescriptive and standardising system design early in the process can minimise many risks. This is being increasingly done via the use of digital technology – in particular BIM and 3D modelling and the adoption of new virtual reality (VR) and augmented reality (AR) immersive environments. These digital tools are a huge part of the standardisation and optimisation process that rest at the heart of a successful offsite and DfMA approach. The New Digital Dreamland As Lorraine McMorrow, BIM & Digital Construction Manager at the McAvoy Group says, this new digital realm is truly exciting. “We have invested a lot of money in getting ahead of the curve in augmented and virtual reality. When you put a headset on and immerse people inside the building and move away from the ‘nuts and bolts’ and show what it feels like when they are inside a building, it is an exciting and different way of engaging people.” The offsite arena has also thrown up new roles and a whole new set of skills required such as logisticians, process engineers, specialists in procurement, digital designers, jobs that go beyond the multi-faceted project manager. The offsite manufacturing world is increasingly a world of specialists. It has to be remembered that the vast majority of construction takes place through traditional methods but issues surrounding productivity,


EOS ROUNDTABLE

quality, embodied energy and waste reduction still apply and have to be improved. And that is a major hurdle to overcome, says Marcus Bennett, Future Skills & Innovation Strategy Lead, CITB. “A significant part of our strategy is how to enable organisations to change their behaviours. I think that the context of anything we do to modernise the industry has to shift progressively. We are also looking significantly at the digitalisation of the construction industry. We think there’s a lot that can be done in this area.” It is not as simple as training people to use BIM or fly drones or assemble things. The issues that are holding back the industry and further progress are more high-concept – such as communication skills, risk aversion to cultural change and a ‘willingness to understand other people’s points of view’. That is what the CITB is ‘trying to shift’. Designing Deliverables One of the leading facilities in the UK helping manufacturers to become more competitive and attuned to advanced technologies and processes is the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC). Jointly funded by Boeing, AMRC is working hard to link skills and strategic R&D and manufacturing methods, to improve construction processes, future-proof job roles and collectively improve UK industry. “For me DfMA in a manufacturing environment and DfMA in construction are two very different approaches,” says Allan Griffin, Head of Construction & Infrastructure Strategy at AMRC.

ATTENDEES Facilitator: Darren Richards – Managing Director, Cogent Consulting Marcus Bennett – Future Skills & Innovation Strategy Lead, CITB Nicola Carniato – Technical Director, AKT II Richard Crosby – Director, Blacc Euan Durston – Associate Partner, Weston Williamson Brendan Geraghty – Director, Geraghty Taylor Allan Griffin – Head of Construction & Infrastructure Strategy, AMRC Kelly Harrison – Associate, Heyne Tillett Steel Jamie Hillier – Pre-construction Director, Kier Lorraine McMorrow – BIM & Digital Construction Manager, McAvoy Group Cian O’Mahony – Chartered Structural Engineer, Evolusion Innovation Mark Riley – Regional Product Manager, Etex BP Nik Teagle - Director, DACS Steve Thompson – Managing Director, EOS Colin Westpfel – Head of Design, Balfour Beatty Mark Wilkinson – Product Certification Manager, SCI

“Basically DfMA is isolating design freeze for manufacture and design freeze for assembly. But what that requires is having ‘manufacturing engineers in design’ and ‘assembly engineers in design’. You can’t get efficiency through a factory until you have the design right at the start. Digital technology delivers information and production details to operators when they need it, so when we have looked at some of these processes with construction companies that ‘make things’ the use of digitisation probably gives them a 50% increase in productivity and huge reduction in errors - digitisation is about the entire process and ultimately moving to the platform of mass customisation.”

Economy of scale rests in repeatability and standardisation, so this and the wider use of DfMA plus the injection of creativity from architects and building designers, can bring about the changes that the construction sector desperately need. So is DfMA the most significant issue to address the mainstreaming of offsite and is there a greater demand for DfMA thinking coming from clients and major contractors? One thing for certain is that the RIBA DfMA Overlay needs to be revised, updated or more importantly re-launched with the wind of the recent 18 months of offsite interest in its sails. Another era of ‘rethinking construction’ and changing

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EOS ROUNDTABLE the mind-set to having a more collaborative and integrated industry as a whole and enabling the kind of joined-up approach that happens in other more ‘progressive industries’ would boost the sector further. This includes the procurement systems that surround the ‘client decision’ and the manufacture/offsite provider’s strengths – much of which rests on that all-important early engagement of supplier and offsite technology expertise. Essentially, the technology needs the collaborative structure to enable it to work correctly and in the ‘right order’. For many within the industry the ‘journey is underway’ on absorbing digitisation of the process and ‘product clarity’. However, there is still a job to be done on making sure that clients need to be very clear about what they want from the building they are creating and matching the ambition to what is being ‘sold’ – perhaps with more of a whole-life focus, with one eye on future adaptation or even end of life deconstruction and repurposing. Don’t Make it Harder than it is The often bewildering terminology that surrounds construction can be detrimental, off-putting and a bad reflection on the sector. “We make it quite difficult for ourselves and for many investors, funders and clients,” says Jamie Hillier, Pre-Construction Director at Kier. “The raft of different acronyms and trying to keep pace with what people are actually describing and talking about is hard. We must ensure that we are talking the same language and understand what we’re talking about. Don’t make using offsite feel harder than it means to be.” “I think the main issue for offsite and DfMA – or whatever it’s called – we have to put the customer at the heart of everything,” adds Colin Westpfel. “We haven’t talked about that much and I also think it’s essential that we collaborate and relentlessly educate. Whether it’s internally or externally, we have a huge responsibility as an industry to produce better buildings, reduce carbon and cut waste.” For certain, DfMA is increasingly seen as a significant way to mainstream offsite technology with controlled repeatability with ‘unbelievable potential’ but it is only one small part of the process ensuring we are

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LESSONS & OUTCOMES Know Your DfMA – although part of the RIBA Plan of Works 2013, the DfMA Overlay is still generally poorly used and understood. Standardisation Matters – ideally a clear set of standardised rules should be in place so that all project parties can understand and work against them. Centres of Manufacturing Excellence – understanding the wider role of technology and learning from the manufacturing strategies behind the automotive and aerospace sectors is critical. Immersive Reality – grasping the huge benefits of the global technology cultural shift – fast becoming the common ground to make client – manufacturer – customer integration easier. Behaviour Change – encourage and guide those unfamiliar with offsite methods on how to become involved via a construction culture shift and developing new job roles. Early Engagement – speak to your offsite supply chain, system provider/ manufacturer early in the design process and agree appropriate ‘design freeze’ stages for maximum efficiency. Collaboration – offsite technology manufacturers, developers, contractors and investors need to develop a closer relationship and understand each other’s building requirements. New Technology and Better Skills – using AR/VR/AI on day-to-day projects will make the construction industry more attractive to younger generations. Sustainability – not enough is said about the green credentials, embodied energy, energy consumption and performance standards that underpin offsite – this is appealing to tenants and the general public. Explaining Costs – offsite manufacture is unquestionably not without risks but they are fewer and more manageable than via a traditional route. Traditional costs are more commonly understood but there are so many intangibles in a traditionally delivered project.

building a ‘cleaner, more practical, more reliable environment that is socially conscious and creates opportunities for people’. To really capitalise on the benefits of offsite and make more progress, the industry language needs to promote the many environmental, economic and social benefits embedded naturally into the DfMA approach – ‘by doing so we create a building to suit the system and not the other way around.” There is a massive and exciting opportunity to deliver the built environment differently. Realistically, offsite manufacture is only part of a wider construction answer to the myriad construction problems the UK faces for the foreseeable future. The future success of offsite rests on a series of key themes – demand creation, capacity building, quality attainment and digital technology implementation. The development and implementation of offsite technology is at a critical phase and ‘on the cusp of a great place’. It is now time to promote the numerous positive aspects of the

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industry that are happening across the UK (and globally if needed) and start to create a consensus around what makes offsite manufacture tick. Then advocate the increasing number of successful projects delivered using offsite methodology – backed by consistent data – and all stakeholders can make the move into new construction practices that go beyond single transactions to forge genuine collaborative and long-term relationships. Many thanks to EOS for hosting the Roundtable Event and thanks to all participants for their time and contributions to the discussion. For more information on EOS visit: www.eos-facades.co.uk For more information on offsite related activity visit: www.offsitehub.co.uk or register FREE to attend www.offsite-expo.co.uk, where the world of offsite will gather to demonstrate the ‘here and now’ of offsite technology and to debate the future of the sector.


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ARUP PLANNING REPORT

REVAMPING THE SYSTEM: PLANNING & OFFSITE

Arup is the latest organisation to publish advice and guidance on how to realise the benefits of offsite construction. The new report focuses on the role of the planning system and how it could reform to boost housebuilding numbers. In response to many issues surrounding planning, construction and engineering consultant Arup, recently published a new industry report: ‘How Modern Methods of Construction Can Deliver ‘More’ Through the Planning System.’ The report finds the planning system ‘too rigid’ to support offsite methods to create the homes the UK needs. The research sought a range of contributions from organisations including: Future Cities Catapult, Greater London Authority, Homes England, social entrepreneur Lord Nat Wei, Mark Farmer, Ministry of Housing, Communities and Local Government, Royal Town Planning Institute and Swan Housing Association. While much industry research has focused on the financial or technical barriers to offsite adoption, the report concentrates on reforms of the planning system required for offsite to truly make a difference. Added to this are the opportunities and actions that could help planning authorities and other users of the planning system utilise offsite to ‘greater and easier’ degrees.

1 As discussed at length in many of this magazine’s Roundtable events over the last 18 months, the sluggish planning system has been a key obstacle in offsite methods delivering the huge level of housing needed across the UK’s expanding communities. Although the profile of offsite has never been higher with acceptance of offsite methods healthy, there is pressure mounting to restructure procurement practices generally

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and make planning a quicker, easier process to navigate – potentially incentivising and offering a fast track option – where certain obligations can be relaxed or refined. There are cases where the time taken to process a planning application is actively hindering one of offsite construction’s key benefits. Likewise the speed at which utility companies are responding to the pace of offsite construction and site preparedness has to be addressed.

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“There’s evidence which shows the current planning system cannot deliver MMC at scale and does not understand the opportunities it offers,” says Vicky Evans, Residential Business Leader at Arup and co-author. “Our research shows 265,000 extra homes could be built in the next 10 years if one-third of new homes built used modern methods of construction. Developers, local authorities and Homes England must now work together to change attitudes and introduce a streamlined planning process that supports innovative housebuilding.”


ARUP PLANNING REPORT So what are these opportunities and actions identified in the report to improve the way the planning system and the offsite industry and its clients operate? One potential answer is the return of the historic architectural ‘pattern book’. “Local planning authorities should consider a patternbook approach embedded within a design code, which could establish parameters for style, daylighting/ fenestration and space standards and implemented using a local development order (LDO), which could indicate the scale of development and site layout.” Local planning authorities should encourage the use of LDOs for offsite developments and “should turn around applications where an LDO is in place within 28 days.” This reduces risk for developers and provides more certainty over planning timescales by ‘front-loading the planning process, through a product-led rather than a project-led approach’. This could provide certainty to developers and speed up the planning process and reduce the burden on already overworked planning departments. “Offsite homes, using pre-agreed design specifications, could speed up decisions, streamline the rest of the process and reduce risk. Securing planning consent is a major milestone in realising the value of a site but too often permission is sought with limited consideration for how homes are going to be constructed. This can result in sub-optimal or unviable permissions, or costly amendments. “Design codes can be used to set out a suite of design options which are all acceptable in planning terms and would enable the local planning authority to identify the external parameters relevant to a particular site or group of sites within which offsite units could be assembled in different combinations and maintain quality across a diverse portfolio of development.” Central to change is a ‘shift in attitude’. “A streamlined, risk-minimising approach will only be possible with a shift in the attitudes of some local planning departments. A pragmatic approach is also needed when applying planning conditions to offsite developments. It’s likely that the impact of construction will be less than traditional housebuilding.”

2 As with many aspects of future construction delivery, the combination of digital infrastructure innovations and offsite could also transform the planning system. “Design ‘evolution’ could be made more transparent by using digital platforms to demonstrate massing and cladding options and planning consent could be secured through semi-automatically generated reserved matter applications sent straight to the production line. This transformation could take place across the built-environment, with modular construction overcoming the complexities and uncertainty of traditional build sites and enabling transparency.”

play a vital role in tackling the housing crisis. It can also help meet planning policy objectives such as increasing the variety of homes and speed of development, enabling homes to be built on brownfield and awkward sites, improving build quality and reducing disruption from construction. MMC is about better products and processes, which aim to improve efficiency, quality, customer satisfaction, environmental performance, sustainability and programme. The MMC revolution is already underway. Now, to enable it to become widely used, all parts of the housing system need to align – and planning is a vital component of this.”

Katie Kerr, Town Planner at Arup and co-author, says: “We see a future system where paper-driven planning applications are replaced with designs direct from digital platforms, selected by the buyer and pre-agreed with the local council, and once consented, are sent straight to the production line.” The report is packed with many wise options and potential solutions for local authorities and planning departments to consider when dealing with offsite delivery and ‘non-traditional’ building design. It summarises by saying offsite, “should

For more information and to download a full copy of Arup’s ‘How Modern Methods of Construction Can Deliver ‘More’ Through the Planning System’ visit: www.arup.com https://bit.ly/328FGBT Images: 01. Bacton Low Rise in Camden. Courtesy Camden Council 02. Offsite methods can play a pivotal role in solving the UK housing crisis. Courtesy Moduloft

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01: ARC BUILDING SOLUTIONS 02: ITW CONSTRUCTION PRODUCTS 05: UNIVERSITY OF INNSBRUCK & ROTHOBLAAS

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01: B&K STRUCTURES, LAING O’ROURKE, BENNETTS ASSOCIATES, BURO HAPPOLD & BINDERHOLZ 02: B&K STRUCTURES, WAUGH THISTLETON ARCHITECTS, ENGENUITI & BINDERHOLZ 03: EDWARD WILLIAMS ARCHITECTS, CUNDALL JOHNSTON & PARTNERS 04: EURBAN 05: FRAME-TECH STRUCTURES 06: GRUFF ARCHITECTS 07: RODERICK JAMES ARCHITECTS LLP 08: STORA ENSO, B&K STRUCTURES AND RAMBOLL 09: WB TIMBER INNOVATIONS 10: WIEHAG GMBH

Education Project of the Year EDUCATION PROJECT OF THE YEAR

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09: TATE HARMER & BLUE FOREST 10: WEBB YATES ENGINEERS PIONEER OF THE YEAR

To view the full shortlist or to book your table for 09 October 2019, visit: www.structuraltimberawards.co.uk or email: amy.pryce@radar-communications.co.uk Headline Sponsors: INSTALLER OF THE YEAR

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PROCESS MANAGEMENT

CONTROLLING FLOW IN A DIGITAL RIVER

Faced with the problem of having to explain a complicated notion it is sometimes helpful to draw on an analogy. Graham Cleland, Director at Berkeley Modular, applies this thinking to the design and build cycle and effective operation and maintenance of residential developments.

1 In many cases, drawing on an analogy with a natural phenomenon is particularly useful if an audience already has some semblance of understanding of the physical entity, and can therefore easily link related concepts. In this instance, I am going to employ the idea of a river as the natural phenomenon that has parallels with the task of capturing the golden thread of information. Consider how, with a river, the volume and velocity of the body of water at the mouth forming the delta is directly influenced by the sources that contributed to the initial flow, plus any further rainfall that might have occurred as the body of water gradually builds over the entire water course. The sources of a river typically flow through independent tributaries before combining at points over the watercourse to form the main body of water flow – see Figure 1. 56

Capturing the golden thread The challenges associated with creating a complete and accurate digital record for a new residential development from conception, through the design and build cycle to practical completion are typically difficult. As with the analogy, the golden thread of information for a residential development emerges from multiple sources and there are many potential points across the design and build cycle where this information can be amended or embellished, or indeed where new information can be created. Like a river, these multiple sources and additional downstream activities have the effect of causing the body of information to steadily grow. Accordingly, the complexity of capturing the golden thread of information for a residential development can be likened to

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controlling flow in a digital river. Often, the initial sources of the golden thread of information are manifold, comprising inputs from the manufacturers of raw materials, components and equipment (i.e. assets) that might be incorporated in a residential development. Subsequent activity facilitates ever-increasing definition of product comprising these assets and also elaboration of build logic which further enhances the body of information forming the golden thread, with the volume and velocity of information generation increasing with time. Again, as with the analogy, a typical design and build cycle does not follow a linear path and is often highly iterative in nature, much like the meandering of a river. Unlike the case with the physical entity, topography in the human-made landscape is actually defined using artificial constructs such as model interoperability schema, execution plans, stipulations relating to organisational information requirements, and information management maps. Additionally, a framework such as the RIBA Plan of Work which helps define broad stages of the design and build cycle to practical completion from Stage 0 (Strategic Definition) to Stage 6 (Handover and Close Out) is usually employed to help maintain design and build activity within the confines of boundaries. These multiple artificial constructs are often configured to be bespoke to individual organisations, or indeed projects within the same organisation, and can be considered similar to the concept of channelling a river between watersheds. In recent times, there have been advances in technology such as digital design software solutions


PROCESS MANAGEMENT and common data environments that can be used to help create a complete and accurate digital record for a residential development. These tools can be considered to represent additional artificial constructs that can help facilitate control of information flow, so in a sense they are also akin to the concept of channelling a river between watersheds. But equally, there have been important changes in the way parties engaged on a project work together which are also yielding influence. Furthermore, we have seen the emergence of new standards and codes of practice associated with the likes of naming conventions, common language definition, data exchange and building of information models, all of which also constitute artificial constructs which are intended to make the process of capturing the golden thread easier. Under normal circumstances, it is easy to comprehend how the fragmented nature of conventional construction approaches cause complexity in terms of information authoring and liability, and subsequent revision control, which acts to thwart and frustrate the process of capturing the golden thread of information to properly support effective operation and maintenance of a completed residential development. This complexity might arise due to a lack of foresight regarding the need to capture and manage information from potential sources ab initio, or from a lack of application of the artificial constructs required to control information flow over the design and build cycle. In contrast to the re-generative nature of a river ecosystem which essentially constitutes a closed loop system, it is often the case that the lack of application or even inappropriate artificial constructs can lead to the evolution of a form of extractive process which is overly linear with many disconnects and embedded wasteful logic reflecting an ineffective approach to capturing the golden thread. Notwithstanding, it is reasonable to take a perspective of end-state requirements and attempt to categorise the information that should constitute a complete and accurate digital record for a new residential development. Such end-state requirements would be somewhat akin to the body of water that needs to form a delta being directly influenced

2 by all sources that contributed to the flow. At high level, these requirements should include: • • • • •

Why was it built? What was actually built? When was it built? Who played a part in the design and build process? How was it built?

This information, constituting a definition of end-state requirements, is captured on the graphic below, along with a rough mapping of the RIBA Plan of Work stages through to practical completion. This definition of requirements provides useful insight insofar as it cements a really important concept regarding information which will provide the basis of the golden thread cannot be created in a single moment in time ex nihilo towards the end of the design and build cycle – see Figure 2. Starting at the source The fact is that despite all the technology improvements, and the significant cultural shift towards more collaborative working, conventional construction approaches are still largely inefficient, and frequently flawed in terms of capturing the golden thread. It is interesting to note that even today there are many organisations across the construction sector involved in residential development who adopt a default position of employing junior level resource towards the end of a project to try to collect and collate relevant

information falling in the categories referred above. Whilst such a position is admirable in the sense it at least represents an attempt to capture the golden thread, it is common that this sort of approach can result in critical information being missed or lost, akin with the concepts of evaporation and spillage to flood plains in the analogy. Of course, it could be argued that these organisations do not really comprehend what creating a complete and accurate digital record implies, because what it should definitely not mean is curating a plethora of scanned drawings and other relevant project documentation that cannot properly support effective operation and maintenance. Much is being made at present of the importance of the construction sector finding ways to leverage productivity, and organisations involved in residential development are not exempt from this challenge. There have been numerous publications, including material from central Government that sets out the aspiration to transform performance with more focus to be brought to bear on leveraging productivity, driving innovation and developing and training new talent. In the simplest terms, the productivity problem can actually be characterised as either generating higher levels of output using the same levels of input, or generating the same levels of output using reduced levels of input.

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PROCESS MANAGEMENT single source of truth for all aspects of operational activity at Berkeley Modular comprising a design and build cycle.

3 Nothing in the typical, conventional construction approach to capturing the golden thread of information is helping to yield improved productivity. This is because the resource typically being employed to collect and collate relevant information are not authoring information, nor are they really managing the same, and often the task is deemed to be unglamorous, so at best they could be considered to represent additional input cost which has limited likelihood of generating the required quality of output from fragmented input sources. Charting an unique course At Berkeley Modular, we have sought to examine everything from first principles. We are a business focused on the offsite manufacture, as opposed to offsite construction, of threedimensional primary structural product (i.e. Category 1 in accordance with the recently published MMC definition framework). We have been afforded the luxury of time to conceive how we can apply lean thinking to information authoring, capturing and revision control, as well as to our manufacturing and assembly logic. The result of this thinking time has yielded a transformative methodology for creating digital connectivity compared to conventional construction approaches. The work we have undertaken to create a Digitally Enabled Agile Manufacturing (DEAM) platform has focused on how technology can help resolve the conundrum of capturing the golden thread of information from the very start of the development process to

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the point of practical completion and handover. This DEAM platform we have developed has been configured to encompass the following: Digital capture of information from source – we have deployed certain options from the coBuilder suite of software to configure the DEAM platform to facilitate a single source of truth for all assets to be incorporated in a residential development. These options represent the tributaries that allow information to be authored by manufacturers’, and subsequently filtered and fed to other components of the DEAM platform. Digital creation of design information – with the help of Majenta, we have deployed certain options from the Autodesk suite of software to configure the DEAM platform to facilitate a product lifecycle management tool wherein digital geometries and build logic definition are automatically linked to asset information in a common data environment. Digital creation of manufacturing instruction – working with DAS, we have deployed computational rulebased logic to obtain high levels of design automation to support the efficient creation of data-rich, fully federated digital models and related manufacturing machine code. Digital management of supply chain, operations and finance activity – we have deployed certain options from the Oracle Fusion suite of software to configure the DEAM platform with an ERP environment which facilitates a

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Digital instruction of manufacturing and assembly activity – We have deployed certain options from the Siemens suite of software to configure the DEAM platform with an MES environment that facilitates a single source of truth for organising and communicating all facets of physical activity performed by Berkeley Modular. These options represent final elements of topography that afford capture of work instruction to both machine and human resource across all factory and site operations, which can be filtered and fed to other components of the DEAM platform. The challenge of creating a productive business operation whilst simultaneously addressing the conundrum of how to capture the golden thread of information has required us to think carefully about digitisation in general, but in particular about responsibility and liability for information authoring, and subsequent revision control. The technological platform outlined above represents certain of the artificial constructs we needed to configure, but in reality this platform is actually supplemented with a combination of other industrystandard and customised constructs that help shape the topography to allow the channelling and progressive capture of information in an efficient, lean manner. Hopefully the insights presented here regarding the complexity of creating a complete and accurate digital record to properly support effective operation and maintenance of a residential development being likened to controlling flow in a digital river represent a useful contribution to the field and will help steer future initiatives towards more successful and rewarding outcomes. For more information visit: www.berkeleygroup.co.uk Images: 01. Figure1 – the flow of a river can be used as an analogy for digital drivers 02. Figure 2 – the golden thread of information follow a complex path 03. Berkeley Homes 68-storey Valiant Tower at South Quay Plaza, London. Courtesy Offsite Solutions


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MODULAR HOUSING

A VISION OF THE FUTURE

When it comes to offsite manufacturing, collaboration is king, says Dave Sheridan, Executive Chairman of ilke Homes, whose firm is at the forefront of delivering quality housing via offsite manufacture.

1 British construction has “dropped like a stone” according to Duncan Brock, Group Director at the Chartered Institute of Procurement & Supply, as the industry recorded its worst month in a decade, based on the construction Purchasing Managers’ Index (PMI). Brexit uncertainty, rising construction costs, an aging workforce and the ongoing skills shortage have all been lamented as causes of the current construction crunch. And while some of these factors are having an effect, the overriding reality is that ours is an industry that has sat back and watched the world Google-ise and Apple-ise without ever really trying to keep up. In truth, the fundamentals of housebuilding haven’t shifted in over a century.

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Construction is an analogue industry trying to function in a digital world. But this is beginning to change. To propel housebuilding into the 21st century, innovation must steer the sector. We can no longer rely on the traditional methods of building – the industry has to modernise. And it is offsite manufacturing that looks poised to drive the innovation that construction so desperately needs. You only have to look at the numbers to see why. Offsite manufacturing can create homes twice as fast when compared to traditional construction, can dramatically reduce onsite waste by up to 90% and uses 67% less energy in the manufacturing and construction process, according to the government’s report into modern methods of construction. In addition,

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these precision engineered homes are more energy efficient, saving consumers up to 30% on their energy bills, the report says. Offsite manufacturing also requires fewer onsite workers, which is extremely valuable given the current skills shortages that plague the industry. We can quickly and efficiently manufacture these homes from start to finish in our factory, from fullyfitted kitchens to flowing bathrooms, and deliver them to site ready for occupation. Precision-engineered in a factory environment, enhanced by 3D modelling technology and with a superior quality to its traditional counterparts - the housebuilding sector finally has its iPhone moment. But like the iPhone, success can only be measured by sales.


MODULAR HOUSING Thankfully for ilke Homes – and for the sector more generally – the momentum is starting to build as the demand for modular homes grows. In May, we signed the single largest modular housing deal in UK history when we agreed to manufacture 750 homes for Places for People, one of the leading placemaking organisations in the country. And we very much see this as just the beginning. We have a current pipeline of 1,200 homes over the next year, with the capacity to manufacture 2,000 in our North Yorkshire factory and plans for additional factories down the line. But meeting the government’s ambitious target of building 300,000 new homes a year will require more than just us – it will require an entire industry. The ilke Homes and Places for People deal shows that the appetite is there, but at the moment the scale is not. To get to that point, collaboration is required. Modular manufacturers and housing providers must work hand-in-hand to educate, invest and deliver quality homes. And to the credit of the sector and the wider market, these efforts are beginning to pay dividends. In April, banking goliath Goldman Sachs bet big on the sector by investing £75million into modular manufacturer TopHat. Meanwhile, Homes England and Urban Splash struck a deal with Japan’s biggest modular housebuilder, Sekisui House, for £90million. These deals show without doubt that the mood is changing on offsite manufacturing. Forging these strategic partnerships is the only way that the sector can continue to increase its capacity. But we also require certainty and stability - things that have always been lacking in construction. Creating certainty and stability was central to our deal with Places for People. Their experience in offsite construction, our strong and long-running relationship between senior leadership, and their burgeoning pipeline meant that this deal was a win-win. It provides our manufacturing facility with a certainty of demand, and their customers with the certainty of high-quality homes. Through this, we can have the confidence that the delivery of highquality, sustainable and beautiful homes will be met at speed and scale.

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3 And once these fully-fitted homes are craned in, they can be personally transformed into the places that people call home. From first-timebuyers, to families sitting on housing waiting lists, our homes are built for all tenures and at a range of price points. But to do this at the scale required to dent the undersupply of homes, the sector must continue to establish strategic partnerships like ours in order to scale-up the modular housing sector and provide homes to those who deserve them. In its current state, offsite manufacturing remains relatively small in comparison to traditional housebuilding. Establishing strategic partnerships, like ours with Places for People, must now be a top priority for all offsite manufacturers and housing providers who seek to overcome market fragmentation and bring homes to the market.

Offsite manufacturing is still an emerging industry but its mass-market moment is on the horizon. To get there, we must collaborate across our sector. Offsite manufacturing will undoubtedly be part of the solution to our housing shortfall, but the real question is whether the industry is willing to change. If it’s not, then we can expect more of the same – a worsening skills crisis, continued questions over build quality and lengthening housing waiting lists. Yet, if we finally decide now is the time to modernise and move forward as one, then offsite manufacturing is poised to deliver. For more information visit: www.ilkehomes.co.uk www.placesforpeople.co.uk Images: 01-03. Offsite manufacturing is still an emerging industry but its mass-market moment is on the horizon.

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MODULAR HOUSING

MODULAR MATTERS IN CROYDON

Standing at 38 and 44 storeys when completed later this year, 101 George Street in Croydon uses 1,524 modules and will be the tallest modular towers in the world delivering a stunning 546 apartments in super-quick time. concrete podium at the points where the modules made contact with the surface to ensure they were level to within 0.1mm.

1 Viewing the project from the nearby East Croydon train station, you recognise it as a construction job, but there is an unshakeable feeling that there is something really different about what is on display and the level of crane activity. This is another impressive project undertaking by Tide Construction in tandem with Vision Modular who have been pushing the boundaries of volumetric modular technology in the UK (and globally for that matter) for the past decade. Atop the two-storey basement, which houses plant and parking spaces, and the ground floor level that will feature a cafe, retail and office space together with an art gallery, you get to the modular-built residential section – a hive of activity with around 150 operatives on site, but without the chaotic feel that is often associated with traditional construction equivalents. Groundworks started in January 2018 with approximately 500 secant piles installed around the perimeter of the site before a two-storey basement was excavated. A further 300 CFA and 62

300 bore piles between 600mm and 900mm in diameter were then installed to a depth of around 30m. With groundworks complete, concrete specialist OBR started bringing up the 38- and 44-storey concrete slip form cores, which rose one storey per day over the course of approximately two months. For stability during the module installation phase and to ensure there is no differential movement during construction, the two concrete cores have been tied/braced together. These are a temporary solution and not essential to the completed buildings. The modules that make up 101 George Street start on the second floor where they sit on a 1.8m thick concrete podium. The podiums were poured in-situ and created at the same time as the cores were erected, so that both were completed at the same time in January 2019, 12 months after work on the site began. To marry the traditional build element with the precisely assembled volumetric modular units required steel base plates, around 450-500mm square each, positioned on the

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The first of the 1,524 modules were craned into position on 22 February. There are 23 different configurations of modules being used on the George Street project, with 38 modules on every level, with apartments ranging from one to three-beds in size, which are made up of two to three individual modules each. These are delivered and installed at a rate of 10-12 modules per day. The team is averaging roughly 1.3 floors per week and will have all the volumetric modules installed by early October. As expected, the modules arrive on site in a remarkable state of completion. The only work required after the modules are fitted together is for them to be cleaned, connected to the building services via vertical connections with other modules and some lateral connections to the core, floor coverings to be installed and some final finishing. Overall, the project is averaging just over 50 module installations per week, making it approximately a 32-week programme to install all the volumetric modules, which will be completed in early October. Cladding, by envelope subcontractor Century Facades, goes up as the modules rise, with installation starting roughly 10 weeks after module installation began. This is speeded up by installing bracketry within the Vision Modular manufacturing facility. The cladding will be completed around two months after the final level of modules is installed meaning that the building should look substantially complete from the exterior by the end of the year.


MODULAR HOUSING Overall the building is due to achieve practical completion in April 2020, just 28 months after the work began, a truly stunning achievement and one that will break the global record for the world’s tallest modular building to boot! Speed is perhaps the most obvious attraction of the modular method, but there are environmental benefits too. The 101 George Street site fills circa one skip every two to three days, compared to around five to six you would see getting emptied every day on a traditional site of this size. Tide Construction claims this means a reduction in construction waste of 80 per cent. The volumetric modular approach also contributes to 80 per cent less vehicle deliveries. On average 10 lorries deliver 10 modules per day. The only other deliveries are occasional ones made by small commercial vans or those associated with cladding panel deliveries, meaning a cut in CO2 of around 50 per cent, according to Vision’s estimates.

Tide and Vision Modular’s work at 101 George Street makes a compelling case for the benefits of modern methods of construction – especially the use of volumetric modular technology. Doing so much work offsite means 101 George Street is a cleaner, quieter site, and one that has yielded no complaints from the neighbours. To see such a record breaking feat being undertaken by a UK manufacturer in the nation’s capital is truly awe-inspiring. Projects of this type open the doorway for other clients to explore this fantastic build method and for other volumetric modular manufacturers to follow suit in time. The shear scale of undertaking and the genuinely ground-breaking speed of delivery means that the 101 George Street project is set to become a true icon of offsite technology delivery.

2 For more information on volumetric modular construction techniques why not register to attend www.modularmatters.co.uk in Birmingham at the end of October, where other pioneers of this leading offsite technology will present on how to get the most out of the systems on offer. Images: 01-02. Worlds Tallest Modular Building in Croydon

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MODULAR HOUSING

COSTA DEL SOL GETS OFFSITE MAKEOVER

AEDAS Homes, a leading publicly traded homebuilder in Spain, has just launched its latest modular project – Vanian Valley. Designed to respond to its exceptional natural surroundings and views of the Mediterranean Sea, Vanian Valley is the first large-scale offsite development on the Costa del Sol.

1 setting of the modules beginning after summer and delivery scheduled for autumn 2020.

2 The development, nestled in the hills outside Estepona on the Costa del Sol’s new ‘Golden Mile’, is half an hour from Marbella and 50 minutes from Malaga’s international airport. The 53 townhouses have a gross development value of €35.3million (£32million) and employ a volumetric 3D steel construction system with steelreinforced cast concrete slabs.

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Designed by HCP Architecture and Engineering, a multi-disciplinary consultancy firm with projects in over 40 countries, the 193 modules that comprise Vanian Valley are being precision-built in a dedicated factory in Toledo by one of Spain’s leading volumetric manufacturers. The total build and installation programme is expected to take 52 weeks, with the

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Each Vanian Valley home has been designed to take advantage of the spectacular views and natural sunlight and overlooks the exclusive community’s pools and green areas. Depending on the typology, the houses have between 156 and 237sq m of floor area, three or four bedrooms, and three full baths. 24 units are laid out on two levels, and the other 29 have two levels plus a ‘tower’ with a rooftop terrace that enjoys panoramic views of the mountains and the sea. All the units have large balconies and floor-to-ceiling windows designed around a lifestyle of yearround sunshine. However, the large number of units and the natural contours of the hillside site posed a unique set of challenges, which made the design


MODULAR HOUSING for manufacture and assembly (DfMA) mindset critical in the planning phase of this project. To respond to the problem presented by the sloped terrain, a two-prong design strategy was employed: in five of the units, each one is comprised of two modules per floor, plus one module for the tower, while the other 48 units rely on a paired solution, similar in nature to the Etheria development in Madrid (see Offsite Magazine Issue 17). In order to maximise the installation of mechanical, electrical and plumbing systems, each pair of houses is comprised of three modules on the ground and first floors, separated by a party wall. 24 units will be topped with a single module to create the tower.

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Logistics is a complex part of the Vanian Valley project, with the distance from factory to site being another key design constraint. In order to reduce the number of trips being made, each module was designed to be exceptionally large, measuring 12-14m long by 4.5m wide by 3.5-4m tall, dimensions which require a specialised truck. As modules are produced in the factory, they will be transported to a nearby empty plot for temporary storage before later being craned into their final location. This technique offers greater flexibility during the setting process and minimises the risk of the truck not being available as the modules roll off the assembly line. Angel Fernandez, Director of AEDAS Offsite Homes, explained how customer needs influenced the company’s decision to go with modular, saying: “Homes in Vanian Valley start at €530,000 (£476,000) and our typical customer is looking for a large second home with an exceptional build quality, stunning views and plenty of light – and they want to be able to enjoy their new home next year, not two years from now. We chose modular for Vanian Valley because of the time we can save, and the control that it gives us over quality. “While many of our customers are from Spain, we do have a significant number from northern Europe, so from a sales perspective, the time savings is really critical for us. If we had built Vanian Valley traditionally, it would have taken at least 24 months. Another plus is that many of these customers, especially those from Scandinavia, are

4 familiar with offsite construction and its advantages, so this makes it especially attractive to this type of homebuyer.” David Martinez, CEO of AEDAS Homes, added: “The Costa del Sol market is extremely competitive – if we can get our homes into the hands of customers faster, that gives us an edge. By year end, we will have launched around 180 offsite homes, and next year we will be scaling this up, so that by 2022, 10% of our deliveries will be offsite. The industrialisation of homebuilding is really reshaping our approach – we are now incorporating high-end modular bathrooms and panelised offsite solutions into many of our traditionally built, multi-storey developments, and we are actively working with suppliers to grow the offsite industry in Spain, which is still in the nascent stage.”

The Spanish home builder targets the mid to mid-high end of the residential market and operates in five major regions: Madrid, Catalonia, the East and Mallorca, Costa del Sol and Andalusia. The company has more than 4,000 units under construction across 64 developments and will deliver roughly 3,000 homes between 2019 and 2020. For more information visit: www.aedashomes.com/en https://offsite.aedashomes.com/en/ Images: 01. Views of one of Vanian Valley’s pools 02. Large modules provide spacious interiors bathed in light 03. Two-storey modular townhouses with modular tower 04. The project responds to the natural contours of the site

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MODULAR MATTERS

SUBSTANTIAL INVESTMENT AND VERTICAL INTEGRATION

Since the last Modular Matters conference and exhibition in 2018, the sector has seen exponential investment and growth, with global brands such has Sekisui House and Goldman Sachs entering the offsite arena. Banking giant Goldman Sachs is investing £75million into modular housing business, TopHat. The modular manufacturer commenced production in early 2018 and has been developing industry-leading technology and manufacturing processes that will shape the UK’s offsite construction sector.

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2 Modular construction is not a new concept, but technological improvements, economic demands, and changing mindsets mean it is attracting unprecedented attention. Today, the sector is experiencing a new wave of interest and Modular Matters, taking place at the National Conference Centre (NCC), Birmingham on 22 October 2019 – will focus on the latest developments, innovations and investments in the volumetric modular sector.

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2019 has been a year of major announcements: Japan’s biggest housebuilder is set to move into the UK modular housing market after striking a multimillion-pound deal that will see it work with Homes England and Urban Splash to bring forward thousands of properties across England. Sekisui House – which builds its assets in factories and then ships them out to sites – is behind the £90million initiative. The agreement will also see a £55million investment into Urban Splash.

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The maturing of digital tools has radically changed the modularconstruction proposition by facilitating the design of modules and optimising delivery logistics. Consumer perception of prefab housing has radically changed, particularly as new, more varied material choices improve visual appeal. The need for faster, leaner and smarter construction is becoming increasingly apparent in the UK. With only 63% of site-based developments completed on time and an even lower 49% delivered on budget, traditional construction methods are failing to meet the major challenges facing the built environment today. We are witnessing a change of approach among constructionsector CEOs, as many leaders see technology-based disruptors entering the scene and realising it may be time to reinvent and reposition. But it is not only investment that is changing the modular construction landscape, radical changes in the supply chain are also being realised. Many of the problems this sector is facing are due to the offsite manufacturing supply chain not being vertically integrated. Developers and asset managers are taking greater control of their supply chains to mitigate the risk of material and skills shortages. Now companies such as Legal and General, Persimmon,


MODULAR MATTERS

3 Barratt Homes and Urban Splash are gaining greater control by investing in land and factories to offer total control and synergy throughout the supply chain to maximise income streams and return on investment. Places for People, one of Britain’s biggest housing associations, has announced a £100m pioneering joint venture with ilke Homes to deliver hundreds of modular houses, as confidence in offsite manufacturing grows. In the largest deal yet for Britain’s modular housing sector, Places for People will purchase 750 units from ilke Homes, including 500 for sites it already owns and 250 for new schemes it will partner to develop affordable and market-priced housing. Modular Matters will demonstrate how to tackle industry challenges through a range of project case studies, innovative architecture and building designs together with software developments. The conference and exhibition will explore what the future holds for volumetric modular construction – technology trends, interoperability, capacity constraints, manufacturing – with presentations from a collection of the UK’s pioneering offsite designers, engineers and manufacturers. Volumetric modular solutions are becoming increasingly commercially viable – structural engineers and architects are now designing and engineering for high-rise modular buildings. It is clear that economies of scale are being realised and modular construction is becoming a truly viable alternative to traditional techniques.

4 Modular Matters will demonstrate the application of volumetric modular technology across a range of vertical markets, including education, leisure, student accommodation, private residential, affordable housing, private rental and specialist applications. The event will focus on the latest developments, innovations and investments in the volumetric modular offsite sector and aims to engage with industry pioneers from within the offsite supply-chain, leading designers, specifiers, engineers and groundbreaking clients. Get Involved This one-day conference will create a platform to learn directly from specialist counterparts on how to apply volumetric modular technology and breaking the myths on design restraints. The event, which will focus around technology knowledge transfer, provides a dynamic and interactive learning experience for all visitors through presentations and the wide array of exhibitors.

Modular Matters provides a positive return on investment and will be one of the most focused events dedicated to the offsite manufacturing and construction industry. Modular Matters is organised in partnership with the Modular & Portable Building Association (MPBA), who play a key role in connecting all sectors of the volumetric modular building industry. For more details on sponsorship or exhibition opportunities go to: www.modularmatters.co.uk/exhibition

Images: 01-04. The 2018 event was sold out and showcased some interesting volumetric modular case studies

BOOK The conference and exhibition have been developed for construction clients and professionals in the public and private sectors, including architects, surveyors, engineers, contractors, facilities managers, building product manufacturers and suppliers. This event presents a great opportunity to gain insight from and network with those who are shaping the future of the volumetric modular industry. Date: 22 October 2019 Venue: National Conference Centre (NCC), Solihull, Birmingham B92 0EJ Tickets: £125 +VAT, which includes refreshments and lunch To book your place, go to: www.modularmatters.co.uk/book

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STEEL

CLADDING: EXPERTISE AND ENGINEERING

Andrew Way, Associate Director at the Steel Construction Institute (SCI), discusses issues surrounding light steel framing with continuous masonry cladding.

2 considered in the design of continuous uninterrupted masonry cladding for LSF buildings, these factors are:

1 Masonry cladding is commonly used on load-bearing light steel framed buildings. The masonry cladding is generally supported from the ground or a podium structure and the light steel frame provides lateral support to the cladding. Depending on the height of the masonry cladding, it may be designed to be vertically supported by the structural frame at specified intermediate floor levels. However, it is

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technically and economically beneficial to consider designing taller continuous heights of masonry cladding which are supported from the ground or a podium structure. Uninterrupted ground supported masonry has been used successfully on light steel framed (LSF) buildings up to eight storeys (approximate height 22m). There are several factors to be

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• Ability of masonry to support its self-weight over the uninterrupted height • Effect of concentrated local loads due to large window openings • Differential movement between the masonry cladding and the light steel structure • Avoidance of disproportionate collapse of masonry cladding • Design of wall ties for local wind loads, especially at corners • Implications for the design of the structural frame. Ability of the Cladding to Support Self-Weight The masonry cladding must be designed to have sufficient strength to resist the applied vertical loads. Openings within the masonry cladding for doors and windows will cause loads to be concentrated in the masonry between openings, this effect should be considered in the design of the masonry.


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STEEL Horizontal Forces for design to BS 5950. Design of Wall Ties The wall ties must be designed to resist local positive and negative wind pressures, which depend on the building location, the building height, the site exposure and the location on the building façade. The required length of wall tie will depend on the cavity width and its embedment length. The required fixing length depends on the thickness of external insulation and the sheathing board. For semi-rigid or flexible insulation, compression sleeves should be used around the fixings to provide the necessary support. Specification and installation of wall ties must be in accordance with the manufacturer’s instructions.

3 Differential Movement Guidance relating to differential movement between masonry cladding and the structural frame is provided in PD 6697 and BS 5628-1. LSF has an advantage in this regard because, as identified in PD 6697, steel frame structures are not subject to shrinkage movement and so vertical differential movement is due only to thermal and moisture movements of the cladding. These effects are accounted for by an allowance of 1 mm/m which is stated in PD 6697 and Chapter 6.10 of the NHBC Standards. Although BS 5628-1 has been superseded by PD 6697, it provides useful guidance which is not directly included in PD 6697. BS 5628-1 recommends that: • Calculated differential movement is less than 30mm • Separate lintels are used for outer and inner leaves • Movement-tolerant wall ties should be used • Soft joints under sills should be provided. An important point to recognise is that BS 5628-1, Clause 25.3.2 ‘Limitation on uninterrupted height’ is applicable to twin leaf masonry cavity walls and that

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the limitations in the clause should not be applied to steel framed buildings with masonry cladding. Disproportionate Collapse Avoidance Masonry cladding should be designed to avoid disproportionate collapse of several storeys of cladding by an accidental event (e.g. vehicular impact). It is recommended that a layer of bed joint reinforcement should be included in the masonry at each floor level. Masonry which is not directly part of the damaged area is tied to the frame through the wall ties and hence is prevented from falling from the structure. Significant vertical distortion of the masonry may occur, but this is deemed acceptable in an accidental load case. Implications for Frame Design One benefit of masonry supported by the ground or a podium is that the light steel frame does not need to be designed to carry the additional weight of the cladding. However, the weight of the masonry supported by the ground or a podium should be included in the permanent actions used for the specific calculation of the Equivalent Horizontal Forces for Eurocode design, or the Notional

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Masonry cladding can be used on LSF buildings with an uninterrupted height of more than five storeys. There is no requirement in either BS 5628 or in BS EN 1996 for masonry cladding to be supported by the structural frame at specific intervals. However, the junction details and ties must make specific allowance for the predicted relative movement. Further guidance with examples of LSF buildings which have continuous masonry cladding over five storeys is provided in SCI Technical Information Sheet P426. The guidance has been produced in association with the Brick Development Association and is freely available to download from The SCI Information Portal. For more information visit: www.steel-sci.com

Images: 01. Masonry cladding on LSF building for an uninterrupted height of eight storeys. Courtesy Metsec 02. Masonry cladding on LSF housing development for uninterrupted heights of five and six storeys. Courtesy Metek 03. Masonry cladding on LSF housing development for uninterrupted heights of seven storeys. Courtesy Sigmat

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LSF ASSOCIATION

MAPPING THE ROUTE AHEAD

As the Light Steel Frame Association (LSFA) continues to grow and gather momentum, we caught up with two founding members for a quick Q&A about the steel frame sector and the offsite market. offsite industry as a whole and light gauge steel will be able to benefit. However, to realise our full latent potential and enable offsite businesses to invest in manufacturing at scale, we need to have confidence in the continuity of supply and I would encourage support by HE into manufacturing ‘infrastructure’. This will be crucial in securing a successful future for offsite.”

1 With a remit to influence legislation and regulation to support the objectives of the steel framing sector, the LSFA is an important industry mouthpiece. Raising awareness of light steel frame technology, its members are promoting and positioning themselves to best meet the busy demands of the construction industry. We posed a few questions on how the light steel sector is faring and where it may be heading to Mike Fairey, Director at Fusion Building Systems and David Ellison, Head of Business Development and Anthony Longbottom, Design Director at Sigmat.

body, progress has been slower than we would have liked. With the LSFA in place, we’ll now be able to coordinate advances being made via digitalisation, material technology, on-site quality checking and share new opportunities with the industry and with our clients.”

Q: How important do you feel the creation of the LSFA is to developing the steel framing sector as a key provider to construction UK?

Q: Is the continuing commitment and support of offsite by Homes England (HE) creating an upswing in interest in light steel frame technology and offsite in general?

Mike Fairey (MF): “It’s something the industry has been lacking over the last 20 years. We’ve been working in the light steel frame sector for that length of time and without an industry

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David Ellison (DE): “Any trade association working for the benefit of the steel framing sector has to be a positive. Raising awareness is key and the LSFA gives credibility and recognition to successful light gauge steel frame to build projects and the sectors they’re successful in.”

MF: “Homes England has achieved significant levels of success by unlocking more development opportunities, from which both the

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DE: “I do believe Homes England’s focus is offsite wherever possible but I feel their interest is slanted more towards volumetric modular than light gauge steel frame. Perhaps the LSFA can look to promote the benefits of light steel frame directly to Homes England for the larger residential apartment schemes?” Q: To those unfamiliar with what light steel frame technology can deliver – what are the performance and productivity benefits of using offsite steel solutions? MF: “Light steel frame systems can be designed, engineered and manufactured to a high degree of accuracy. This enables it to be integrated with other accurately produced components, making it the perfect skeleton around which to build a digital construction offer. Light steel frame systems are a platform for a step change in both material and labour productivity with safer sites, faster more reliable programmes, and greater assurance of performance/ quality plus with a digitally integrated supply chain – lower project costs overall.” DE: “Light steel frame can offer a better cost plan in terms of an upfront commitment to finance and pay for a scheme when compared to volumetric modular. When appraised


LSF ASSOCIATION

2 against more traditional methods of construction, the onsite health and safety benefits that a small installation team can offer are greatly under represented. The build process can be circa 40% quicker than traditional methods of construction and allow the introduction of follow-on trades to accelerate the build programme. It also results in an earlier return upon investment for the client.” Q: How important is BIM and new digital tools including AR/ VR to developing more efficient manufacture? What do you think of the new PRISM app – what benefits will it have for the manufacturing community and the steel sector? MF: “A few years ago the introduction of BIM was viewed by some as a new ‘tick-box’ requirement to secure business. Our approach has been the direct opposite, we have invested into software throughout all areas of our business, which is now proving to be highly significant in our ability to manage the requirements of the Hackitt Review: Applying ‘Golden Thread’ methodology to deliver a virtually integrated supply chain from concept, to design, to completion on-site. When this is coupled with other modern software innovations, we’ll be in a position where we can provide total quality assurance and regulation compliance throughout the construction process. “The new PRISM app is a positive step forward to achieving a digitally-led industry. I have heard a number of initial comments and in general they are all positive. The ability for anyone to access PRISM via an app on an open source basis, which will assist them at a very basic level with project benchmarking and to review designs from concept stage against a number

3 of potential offsite manufactured systems, can only be a step in the right direction. I’m sure over time the app will be developed and improved as feedback is received.” Anthony Longbottom, Design Director, Sigmat: “BIM is an invaluable tool for speeding up the approval process especially when considering integrated services and increased collaboration with other disciplines. The implementation of AR/VR will only help to improve this process. PRISM looks more like software that will be good to visualise the building but not necessarily for use in manufacture. Sigmat is a highly accurate system and as such is modelled with bespoke components within Tekla Structures – a structural detailing package. At present we do not have the facility to manufacture direct from PRISM but it may be something to look at in the future.” Q: Where do you see the light steel frame and offsite sectors heading in the next 18 months? What key projects are you presently working on? MF: “The adoption of the recommendations of the Hackitt Review will be a game-changer and I see the industry heading further towards digital integration and in turn, enhanced quality and compliance requirements. We’ll see evidence of Golden Thread methodology through virtual supply chain integration delivering high quality design and site installation. I think we will also see changes in procurement models – challenging compatibilities and consolidation, which we’ve worked on for the past seven or eight years, to reach a level where Golden Thread thinking is fundamental to each project.

4 “In terms of Fusion Building Systems, we will continue to invest significant sums in to R&D in order to optimise of our service and product offerings, looking to further develop supply chain partners in order to continually be able to provide proven and tested solutions which drive the Golden Thread thinking. I foresee little change in our key markets: housing, mediumto-high rise apartments, student accommodation, care facilities, hotels and schools but huge change driven by the adoption of offsite solutions, the Hackitt Review and how this impacts interaction with, funders, developers, consultants and main contractors.” DE: “If you ignore the prospect of a troublesome BREXIT, the light steel frame sector will continue to grow. Sigmat are planning to expand our manufacturing efficiencies and in turn our output in order to service what we see as a growing market and appetite to build in this way. New players are entering the market so obviously see the potential of this growing market. Sigmat are working on a number of key projects and are happy to share our successes with the LSFA at an appropriate time.” For more information on the LSFA and how to become a member visit: www.lsf-association.co.uk www.fusionbuild.com www.sigmat.co.uk Images: 01. Installation of Fusion’s offsite light gauge steel frame at Neville’s Cross. Courtesy Fusion Building Systems 02. Mike Fairey, Director, Fusion Building Systems 03. David Ellison, Head of Business Development, Sigmat 04. Offsite manufacture introduces a range of efficiencies. Courtesy Sigmat

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INTERNATIONAL OFFSITE

A GAME CHANGING MOMENT FOR MODULAR CONSTRUCTION

Last issue we reported on the world’s tallest modular hotel nearing completion in New York City (NYC). We follow up with a quick overview of the 6th Avenue Marriott AC NoMAD approach by Henry Mickleburgh, Executive Vice President at Skystone LLC.

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1 Skystone is acting as the general contractor and approved Marriott modular manufacturer for the Marriott AC Nomad on 6th Avenue. The project consists of 168 rooms over 26 storeys and is located on 6th Avenue, Manhattan – between 29th and 30th Street. With modular and pre-furnished guestrooms plus a modular roof and modular rooftop bar, Skystone is proud to deliver what will be on completion the world’s tallest volumetric modular hotel on a turnkey basis. The existing site contained a typical Manhattan low-rise 1980s commercial building that required demolition by Skystone’s expert team and considerable underpinning of adjacent buildings. As an approved Marriott modular manufacturer, we maintain a

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strong relationship with Marriott’s senior management team, who are spearheading their modular initiative across their construction footprint. For a number of years, we’ve worked closely with Dave Walsh, Senior Director, Project Management, The Americas and Jennifer Abuzeid, Senior Director Global Design Strategies at Marriott International, so when the opportunity arose to deliver an AC on 6th Avenue – just around the corner from our NYC offices – Skystone put everything on the table from Day 1 to realise it. From a general contracting perspective the project is challenging, but reasonably generic. Consisting of four reinforced concrete storeys and central lift/stair core, the overall project budget split is roughly 65% vs 35% base build to modular methods.

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3 Whilst we work in a transparent, collaborative and negotiated manner, our mantra is based upon being ‘civilised megalomaniacs’ and this usually requires our remit to cover the entire project, or ‘turnkey’. We own all of the validation, inspections and approvals for every part of the supply chain to suit each project’s geographical and legislative context. In the US, we are licenced general contractors on both East and West coasts. For the UK, Ireland and some of mainland Europe, we provide turnkey solutions via our joint venture with macskystone. We have embraced digital tools to make each step of the construction process as streamlined and efficient as possible. The Skystone app allows real time viewing of all modules. QR codes are embedded to each module


INTERNATIONAL OFFSITE

4 that allows necessary inspections, logs and progress to be instantly viewed and checked against the lifetime of the modules. A ‘cradle to grave’ paint by numbers process, based upon self-improving iterative stages, that’s linked to collaborative software and a fiercely guarded ‘knowledge bank’ of continuously improving microstructures, forms the backbone of Skystone’s controls. Our patented ‘Skystone Microstructures’ are highly developed, multi ‘D’ BIM models, linked to collaborative software, which allows us to manage our global supply chain partners across time zones. In order to put 6th Avenue into context, one needs to understand the Skystone production operation. It’s necessary to provide an understanding of our business model and how this alters from the generic, industry paradigm that volumetric modules are produced by ‘a factory’. Many years of volumetric experience has provided us with a unique understanding of the best and worst aspects and it’s this understanding that informs the premise of our business model. We understand that our modules are highly complex, manufactured products and like any product of this nature – a car or smartphone – it’s about identifying, managing and harnessing the best supply chain and maintaining overarching controls and accreditation for that product. As per the smartphone/car analogy, it’s necessary to consider this paradigm shift in production methodology against our approach to various regional markets, as this model allows us to source the best ‘parts’ of our product over global supply chain options. This approach allows us to control every aspect of the supply chain, ensuring quality and validation under our protocols.

5 Mainland Europe to the USA For 6th Avenue, we have used our Polish supply chain. The volumetric modular remit is divided into the following seven constituent parts – see image 5. Like the chassis of a car, the structural cages are the most critical portion of our modules. STP Elbud, provided us with the enthusiasm, capacity and quality required to meet our requirements. Together we developed a rotating jig that enables full weld access without resorting to manual rotation increasing productivity and maximising robotic welding. Full inspections have resulted in all cages being produced within a +/- 3mm X, Y and Z directional tolerance. Added to this we used Aluprof – a global leader in façade systems – that have impeccable accreditation and a strong history of high-rise facades in Manhattan and provide impeccable quality. DMD Modular’s facility’s size allowed us to produce all 168 rooms under one roof, and securely store in controlled environments Skystone’s specialist items as dictated to by Marriott’s brand standards. This allowed Skystone to embed our team and protocols into their production facility. In consultation we improved their considerable facility to suit our standards and via the development of two full-sized prototypes, assessed, trained and developed their workforce to the demanding standards required by Marriott’s 4 Star AC Brand. The quality of finishes achieved by DMD’s workforce is undoubtedly world class. Skystone’s team and inspectors are fully-embedded into DMD’s facility and ensure that every module is produced to the exacting standards required by Skystone’s procedures.

All modules will be transported from DMD’s facility to the Port of Gdansk, then offloaded at the Port of Red Hook, NYC, staged ready for just in time installation at 6th Avenue. Each module is GPS tagged and the same methodology used at final factory inspection is used at both ports. This methodology enables Skystone to determine robust ‘themes’ informing the current and future production. The prototype rooms were transported, shipped and received in San Diego, late 2018 and this data was used to clarify robustness. We are pleased to report that very minor effects were incurred during this considerable trip. Expected to open in late 2020, the building is proving to be a ‘gamechanging symbol’ in modular construction and displays all the positive facets that offsite manufacture can deliver. In fact it has been described as a ‘hotel that takes every advantage of offsite manufacturing but does so in a way that defies expectation’. Hopefully this project will make everyone across the globe aware of what modular construction is capable of at scale. For more information visit: www.skystone.com www.macskystone.com www.marriott.com Images: 01. On completion the 6th Avenue Marriott AC NoMAD will be the world’s tallest volumetric modular hotel – just around the corner from the Empire State Building 02-04. The steel framed modules are transported from Poland where Skystone’s team and inspectors are fully-embedded into DMD Modular’s facility to ensure that every module is produced to Skystone’s exacting standards and procedures 05. Proportional breakdown of modular scope

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TRANSPORT CHALLENGES

TRANSITION: SITE TO OFFSITE

The move of construction works with tradespeople performing site based works, either sub-contract or direct for main contractors, to a factory-based production line is not going to be as easy as many might think. Stephen Boyd, Managing Director of Building With Frames (BWF) explains more.

1 Offsite certainly has a lot of drive at the moment and some may believe there are big financial rewards for those that win the big contracts, which means there will be a lot of new companies being formed and sales departments seeking the big deals. If you think of it in simple terms all that is needed is a formula for costing boxes or wall panels, then scale it up for larger projects and it should all fall into place with a nice mass production economy of scale and profit margin to suit. However, some may be too hasty to agree deals where they have underestimated the scale of works involved in the project delivery. Billions are being invested in developing new factories, researching systems around the world, building corporate management teams, importing machinery and negotiating contracts. And why not, if it is as simple as factory car production where they just roll off the line and get delivered to site in the chosen colour or cladding. Where I believe it will not be as simple is in the variables – of which there are so many to check and it takes very experienced teams to identify them. The experience takes years to build and is often dependant on location,

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2 where some may deal with projects down narrow lanes whilst others deal with motorway routes, some may have to deal with sloping sites whilst others have flat sites and so on. It is essential to identify at the point of sale where there is soft ground, overhead cables, access routes, and turning points, understanding low loaders, cranes, using curtain side trucks or flatbeds, loading and unloading methods and weights. This is to name a few of the variables just in the transport and then there are the extensive variations of product specification, client requirements, delivery schedules, how these affect production rates and then the material purchasing, storing and labour, design and engineering resources. This skill and experience cannot be simply brought in like a factory production line from overseas, but it can be found in many of the smaller local companies involved with offsite in every county, whether the company supplies steel frame, timber frame, panelised products, volumetric or modular units. One of the best ways to source these companies is often through a local framework or procurement group, where the company checks have already been

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3 made, otherwise a check on previous work and clients will be essential. Now is a good time for Councils, LEPS, housing associations, investors, developers and clients to collaborate with their local SME’s that are keen to grow, but either need the consistent pipeline, support or investment. That will enable them to create better job’s, develop training schemes, take on apprentices and source better machinery with a development plan for the future and the higher skilled employment of the future. For more information visit: www.buildingwithframes.co.uk Images: 01-03. Many variables need to be considered with offsite methods including access routes, turning points and crane usage


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TIMBER

CLT – IT’S HERE TO STAY

Cross-laminated timber (CLT) has been the timber industry’s game changer since its conception and for good reason, yet the unpredictable events of the last couple of years show some refinement of the system is required. Rupert Scott, TRADA’s Membership and Marketing Manager, explains more.

2 Most attempts to dissuade the use of CLT citing durability problems are overly sensational. It’s true that some issues with CLT can be traced back to high moisture levels, resulting from trapped construction moisture, poor design or leaks from the failure of other components, however, the effects of moisture can be managed, both during the construction phase and when buildings are in use. For example, CLT buildings can be erected quickly, but larger structures still take several weeks to build. In this scenario, it is important that contractors understand the importance of installing a weathertight shell as soon as practically possible, and the urgency of water management procedures which include deflection and drainage.

1 Industry headlines seem to oscillate between the global climate crisis, the excitement of building large and building tall, and building safety in a post-Grenfell world – three areas in which CLT continues to have a role to play. It will undoubtedly, perhaps necessarily, be put through the wringer in the months to come but supporters of the material shouldn’t be alarmed.

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Changes to Building Regulations postGrenfell now prevent CLT from being used in the external walls of high-rise residential buildings over 18 metres, which includes structural members within their scope. This means that CLT must be used within the building itself, e.g. post and beam construction, which is possible if more restrictive.

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There are timber frame buildings which are hundreds of years old – we have every reason to believe that engineered timber buildings will enjoy the same durability, presuming good principles of construction and encapsulation are followed. Maintenance is also key to longevity. Here at TRADA, our stance has remained clear: CLT is here to stay. The benefits of the material are just too advantageous to ignore. In a time of climate crisis turmoil, the existence of a renewable resource


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TIMBER TRADA PUBLICATIONS & CLT

3 which sequesters CO2 is indispensable. No other material possesses the same power for carbon neutrality – something we should be seizing on as a nation following the Government’s commitment to net zero greenhouse gas emissions by 2050. However, its excellent environmental credentials are not its only strength. Yes, all structural building materials have their investment advantages and disadvantages. At a first glance, CLT can cost more upfront than other materials – but like-for-like cost comparisons cannot do CLT justice because they are unable to take into account the very real cost savings that can be made as a direct result of programme savings, strength-toweight ratio and other environmental factors. To clarify, using engineered timber can shorten the build time by 10–20%, and involves significantly fewer deliveries, site storage requirements and construction waste than other materials – reducing both associated risk and costs. There is a reason CLT is a favourite of time- or planning-sensitive projects such as schools and hospitals, where on-site time is limited and any disruption in the form of noise, dust or waste can be damaging. While using the material has no overt influence on securing viable planning consent, CLT has many benefits over other structural materials in their areas of concern, some of which have already been mentioned. The material lends itself to many forms of offsite construction. In fact, timber offsite construction market

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4 share is improving year-on-year. In combination, they result in a building which assembles quickly, on a safer, cleaner site that produces less waste and dust and – most importantly – is more likely to be delivered on time. If a project is constrained by building height restrictions, CLT should be a contender as it has low floor-to-floor dimensions. If it’s innovative design you’re after, CLT’s capacity for wide spans or novel-shaped windows and doors might be a source of inspiration. Finally, CLT is a possible answer to another crisis our nation is currently undergoing: mental health. Research is mounting supporting timber’s positive impact on our health and wellbeing, aligning it with biophilic design. CLT can be left exposed internally, resulting in a powerful finish – supporting worker physiology, sentiment and productivity. What more can you want? All these characteristics, in addition to sequestering carbon, make it a strong competitor. Here at TRADA, we are certain it is here to stay. TRADA provides a wide range of independent, authoritative publications and technical guidance on timber for construction professionals. For more information on CLT and its benefits, you might be interested in the publications ‘Cross-laminated timber: design and performance’ or ‘Procuring engineered timber buildings: A client’s guide’ which are both available in the TRADA Bookshop. For more information visit: www.trada.co.uk

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‘Procuring engineered timber buildings: A client’s guide’ highlights the important questions developers and other clients need to consider when reviewing the merits of engineered timber solutions for the structure of their building. The publication will assist TRADA members in providing answers to the following questions and may be shared with their clients. Points covered include the key considerations for engineered timber during design and construction, perceived insurance risks and relevant issues for securing viable planning consent plus how does the cost of building with structural engineered timber compare to building with other structural materials and why it is important to understand the technical parameters imposed by building with engineered timber. ‘Cross-laminated timber: design and performance’ has been written to cover the design and performance of CLT within construction. Chapter 1 showcases its uses for architects and building designers. Chapter 2 focuses on design principles and Chapter 3 covers CLT performance, including structural design, fire performance, acoustics, thermal performance, durability, appearance, and sustainability. Chapter 4 concludes the book with thirteen case studies based on several building types. Highly illustrated with photos and technical drawings, this book demonstrates the versatility of CLT as a sustainable, engineered timber solution and will assist architects, engineers and their clients looking to work with this material.

Images: 01-02. The benefits of engineered timber are just too advantageous to ignore 03. ‘Procuring engineered timber buildings: A client’s guide’ 04. TRADA’s Rupert Scott and broadcaster Kevin McCloud with a copy of ‘Cross laminated timber: design and performance’

VISIT TRADA AT OFFSITE EXPO


This building grows back Today we can build higher, stronger and lighter than ever before with a raw material that is renewable. By using wood in construction we can help cut CO2 emissions by up to 75%. It’s time to make the switch from fossil-based materials. Welcome to the renewable materials company. www.storaenso.com/ReduceCO2Emissions


CASE STUDY

TIMBER HYBRID

ALL SORTED WITH HYBRID CONSTRUCTION

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An innovative internal hybrid CLT and steel frame solution has been used to transform a derelict 1855 Post Office on Islington’s Essex Road. The Old Sorting House, by Ben Adams Architects for Martin’s Properties, has achieved BREEAM Excellent and is a standard bearer for sustainable preservation. The scheme is formed of three original buildings which have been refurbished to create a new ‘in-between’ building that provides a large, airy office floorplate over four floors. The roof of the original post office has been raised to achieve a new top floor which includes a spectacular mezzanine. Working with an existing building in a conservation area meant there were strict height limitations relating to the raising of the roof, and the slimmest possible structural build was needed to achieve the required quantity of accommodation. Everything above the existing basement and ground floor level was removed to incorporate the extra storey and using a hybrid cross laminated timber (CLT) and steel frame structure enabled the reduction of floor depth by between 50 and 75%. Structurally, the CLT slots into the sectional zone of the steelwork which achieves this efficient floor plate. Combining the two materials has made better use of the building fabric as the steel helps restrain the exterior walls of the building, effectively enabling the floor plates to be pulled inward.

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“Internal comfort was a key consideration. Bringing light into the right places is a key factor and creating an environment that feels warm and pleasing is very important when working within the constraints of existing buildings,” adds Nick.

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“I can’t over emphasise the constrained ceiling heights. So making sure we have something that is a natural material, is pale in hue and allows reflected light to be bounced within the environment really helps increase the sense of wellness in the space and the lightness of the environment for the office users.”

A triple height void has been created along each end of the major floor plates which visually connects the basement, ground and first floors while also allowing light into the basement. “Specification of CLT was the obvious solution in many ways.” Explains Nick Jewell, Senior Consultant and Head of Research at Ben Adams Architects. “Access to the site was particularly constrained and complex because we were retaining the existing facades of the building and incorporating the new CLT and steel structure into it quickly. Using CLT meant we could make everything offsite, which really helped to cut down time in terms of creating new floors and a framework to get the building weather-tight.” Hybrid construction specialist B&K Structures installed the hybrid frame in just 19 weeks. Internally, the CLT is left exposed throughout and has been treated with a spread of flame treatment which achieves a Class A fire rating, and gives the material a white opaque appearance while still allowing the grain and quality of the wood to be clearly visible.

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Harvey Walker, Stora Enso’s Sales Manager for Building Solutions in the UK and Ireland, says: “We’re increasingly seeing CLT used in the adaptation and re-use of historic and disused buildings and looking at Old Sorting House it’s easy to see why. By embracing the structural and design benefits of CLT, Ben Adams Architects and Martin’s Properties have created a spacious, welcoming space that will extend the life of this wonderful old building for many years to come.” For more information visit: www.storaenso.com Gareth Mason, UK Business Development Manager for Stora Enso will be presenting a case study on Ellerslie Road Development at the Timber Talks Seminar on the 06 November at the Building Centre London – for more information, go to www.timbertalks.co.uk

Images: 01-03. The Old Sorting House is an example of what can be done with CLT within a historic building context. Courtesy Jack Hobhouse


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TIMBER

GET MORE FROM YOUR STRUCTURAL FLOOR EGGER Protect is the only chipboard flooring on the market, that once laid, can be exposed to the elements for up to 60 days.

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Manufactured from EGGER P5 flooring grade particleboard, EGGER Protect features a durable, anti-slip, weatherresistant surface layer applied to both sides of the board, resulting in permanent protection from moisture ingress before, during and after the build. The robust surface of EGGER Protect has major benefits on site: the board can be fitted in light rain conditions, has proven anti-slip properties even when wet, and is suitable for use as a working deck. Rough edged materials can be shovelled without damaging the surface of the board and tough materials such as dried cement and plaster can be scrapped off with ease, leaving a clean floor ready for handover. The 60 days exposure of the board gives extra security when delays happen onsite, whether down to bad weather, materials not turning up or a shortage of labour. It is the only board 84

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that we recommend tiling directly onto and it can also be used with underfloor heating systems. When used as part of the EGGER Advanced Structural Flooring System, the fully sealed surface on both sides of the board will prevent water damage caused by leaking washing machines and burst pipes throughout the life of the board within the build. To achieve optimal results when laying EGGER Protect, seal the joints and board edges with EGGER Joint & Joist Adhesive. Designed to make laying floors simple and quick, the D4 adhesive is five times stronger than mechanical fixings and thanks to the unique foaming action, helps to minimise board movement and squeaks often associated with a fully nailed floor. Each board has a tongue and groove profile that is cut with unique diamond-tipped tooling which creates more consistent joints in the board.

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When used as part of the EGGER Advanced Structural Flooring System, EGGER Protect is covered by our EGGER Advanced Lifetime Guarantee. To benefit from the guarantee, simply follow three simple steps: select your flooring board from the EGGER Advanced Structural Flooring range, use EGGER Joint & Joist Adhesive and fit in accordance to the EGGER Fitting Guide. For more information visit: www.egger.com or contact Georgina Benton, Marketing Specialist (Building) email: georgina.benton@egger.com EGGER Protect • Dual-sided protection against water and moisture ingress throughout the life of the board • Once fully fitted, can be exposed to the elements for up to 60 days • Ideal for direct tiling and use with underfloor heating systems •

Covered by our Advanced Lifetime Guarantee when used as part of the EGGER Advanced Structural Flooring System.

Image: 01. EGGER Protect, with dual-sided protection which protects the board from moisture ingress 02. The three steps in the EGGER Advanced Structural Flooring System to achieve the Lifetime Guarantee 03. EGGER Joint & Joist Adhesive, used as part of the EGGER Advanced Structural Flooring System


Egger Protect. 60 days protection, whatever the weather. www.egger.com/60-days

It’s a fact – house building and renovation projects are often delayed, leaving sites under threat of weather damage. EGGER Protect is an advanced structural flooring board that can be exposed to the elements for up to 60 days. The unique dual sided surface offers permanent protection from moisture. And, as part of the EGGER Advanced Structural Flooring System, it comes with a Lifetime Guarantee. For more information, call 0845 602 4444 or email building.uk@egger.com.


CONCRETE CREATIONS

BEAUTIFUL BUILDING

Beauty is in the eye of the beholder – a phrase that neatly sums up the work of the government advisory Building Better, Building Beautiful Commission. Elaine Toogood, Senior Architect, The Concrete Centre, illustrates how concrete helps deliver a bespoke, natural aesthetic and superb structural performance.

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Created to promote and increase the use of high-quality design for newbuild homes and neighbourhoods, the Building Better, Building Beautiful Commission recently issued their interim report ‘Creating Space for Beauty’ with their final recommendation expected in December. With a subjective premise such as beauty at the heart of the initiative the question is how can this influence design? And how does beauty interact with quality and quantity? Is the risk of offsite solutions that spaces will be dominated by the monotony of repetition and produce unstimulating places?

behind an embedded layer of brick or stone. In fact, offsite construction using architectural precast concrete is uniquely placed to create high quality buildings, with interest and delight.

The selection and design of the materials that will remain visible in a development is key to securing beauty and great place making - and the report identifies this for consideration at building scale. Precast concrete cladding offers designers such a range of aesthetic options that there is no need to compromise on beauty, quality or speed of construction.

Form, colour, texture shape of architectural precast concrete can all be selected and designed to suit location. Natural sands and aggregates are the principle means of providing colour, creating the opportunity to enhance or reference local vernacular, without pastiche. Pigments can also be added to great effect. Natural, earthy colours are most common, but greens and blues are also available.

As I explored in more depth in Issue 9 of this magazine, contemporary, architectural precast concrete is as likely to resemble Portland stone, black polished marble or have a patterned relief in terracotta. It may not even be perceived as concrete at all, hidden 86

Sophisticated moulding, advances in mixes and a greater variety of finishing techniques mean that exposed precast concrete can demonstrating craftmanship and intricate detail. Elaborate brick detailing, with stepped corbels, for example, becomes costeffective when factory manufactured as brick-faced concrete cladding, as illustrated by Maccreanor Lavingtons Garden Place student housing.

New digital manufacturing techniques for formwork such as five-axis routers, greatly simplify the creation of complex and ornate shapes, texture and pattern. Reusable formwork liners can also create varied textures

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3 and pattern, ranging from stone or even timber textures, to bespoke ornamental features. To just talk about façade design in the context of this debate for improving the quality of the building environment falls way short of the myriad of issues that need to be addressed and which have been included in the report. Architectural precast concrete offers many opportunities to contribute to the creation of beautiful places, as well as its other acknowledged benefits such as fire protection, low maintenance, durability, safety and speed of installation of site. Maintaining performance and aesthetic quality over the long term should be equally, if not more important to good place making. For more information visit: www.concretecentre.com Or see us at Offsite Expo on 24-25 September at stand D17 Images: 01-03. The moulds for the full height architectural precast tracery of St Peters Square in Manchester by Simpson Haugh, incorporate CNC machined elements, manufactured from digital models. The design directly references hand-carved stone motifs of the nearby Manchester town hall.


Guidance from The Concrete Centre Concrete is inherently suited to tall construction, with the many benefits that concrete can provide including fire resistance, thermal mass, acoustic separation and robustness. These benefits assist with the construction of buildings that are safe, cost-effective and easy to maintain or accept change-of-use. Two recently-published guides on tall buildings are available to download from The Concrete Centre website. These publications highlight the methods of construction available along with examples and benefits associated with their applications, together with case study exemplars. www.concretecentre.com/publications

www.concretecentre.com @concretecentre Image: 24-25 storey towers at Hoola development, London. Š Jack Hobhouse


MODULAR BALCONIES

NEW METHODS DEMAND FRESH BALCONY SOLUTIONS

Balconies make apartment buildings more visually interesting and give residents some ‘outdoor’ space, enhancing marketability. New materials and systems for offsite manufactured buildings bring fresh balcony challenges – sparking Sapphire’s ingenious modular solutions. A key challenge with many MMC building solutions is ensuring that balconies are rigid. The most important structural element is the unseen balcony connection back to the building. If it’s not right, a balcony could feel ‘bouncy’, corrode more quickly, have poor thermal performance – or even be a safety risk. Where there’s a reinforced concrete frame, there’s no problem because balcony brackets can be securely cast-in or post-fixed. But with timber or steel MMC framing systems, it is necessary to use alternative connections that tie back further into the building.

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2 Modern methods of construction (MMC) is a smart way to meet the high demand for new homes in London and other major towns and cities. Scarcity of land drives the move to high-rise homes, across the spectrum from highend luxury down to social housing. By adopting MMC framing and infill solutions, architects, developers and contractors are able to deliver homes of appropriately high standards more quickly and at market-related prices.

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Sapphire Balconies, a leading manufacturer of balcony systems for residential applications, has added its muscle to the modular revolution by giving architects wide scope in balcony design – combined with the reliability of modular construction. Sapphire has developed a lightweight cantilevered solution that makes a balcony as much at home on virtually any offsite construction method as it is on a traditional thick reinforced concrete structure. This gives architects the confidence to design balconies that balance all requirements – visual, practical and financial. This is true for a wide range of offsite materials and practices, such as cross laminated timber fames, steel frames, thin concrete slabs and precast wall panels. Key to Sapphire’s Glide-On™ Cassette® system is its lightweight, modular construction, which reduces forces on the anchors and connections that transfer the load of the balcony to the structure of the building. This is particularly important, where structural elements are less rigid than reinforced concrete.

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Several connection alternatives are available, and all are designed to outperform L/180 structural requirements, include thermal breaks and can be used with or without stub brackets. Frames of Sapphire’s GlideOn™ Cassette® – which is attached to the support arms – are made of laser cut and mechanically fixed aluminium, making the balcony one third the weight of a comparable all-steel design. The smaller load may reduce the number of supports required, the number of façade penetrations and the risk of cold bridging or damp problems. Unlike traditional balconies, Glide-On™ Cassette® balconies are fixed to their anchors from above so soffits can be factory installed, reducing the finishing works and overall costs. These balconies allow a choice of materials for soffits, decking and balustrades, although Sapphire recommends Class A aluminium soffits and decking to minimise any risk of fire spreading. Balconies are fully assembled to architects’ specification at Sapphire’s factory and transported to site. Each is delivered pre-assembled and factory finished to a high quality standard, so there is minimal need for on-site finishing. For more information visit: www.sapphire.eu.com/technical-info/ offsite-production-benefits

Images: 01-02. Sapphire balconies give architects the confidence to design balconies that balance all requirements – visual, practical and financial.


Explore our proven modular solutions www.sapphire.eu.com/ case-studies/pomonawharf-trafford/

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CASE STUDY

DIGITAL DESIGN

JUST IN TIME – THANKS TO TEKLA AND MODULAR CONSTRUCTION slightly (the hot-roll elements were outsourced), we had to process the two materials separately. However, it was vital that we were still able to design both elements concurrently within the same model, for they could not be designed in isolation. Fortunately, Tekla Structures allowed us to do exactly this, saving valuable time. “Furthermore, Tekla software is also able to work with a variety of different building materials. For example, while modelling the light steel structure and its connections to the main building, our designers were also able to see the concrete podium level at its exact location in the same model. Working in 3D in this way is far more effective than the previous 2D drawings.”

1 Intelligent Steel Solutions Ltd (formerly known as Icarus LSF) used modular methods during the construction of Vita Student Westgate, as well as Trimble’s Tekla software to assist with the designing and manufacturing of the building. Modular construction has been around for many years but is increasing in popularity as a preferred building method within the UK construction industry, favoured for its efficient assembly speed and cost savings. The project – a large student accommodation scheme located in central Newcastle comprising of over 280 units – was heavily timecritical, with vital competition dates and students due to move into the accommodation at the start of the new academic year. As a result, Intelligent Steel turned to Trimble’s Tekla software to assist in designing, manufacturing and constructing the six-storey building, using off-site light steel frame technology. 90

“After using other metal framing systems in the past, we now only use Tekla Structures for all modelling and data output of GA drawings, Panel drawings, CSV data and reports,” says Crystal Williamson, Designer Manager at Intelligent Steel. “Tekla is more user-friendly than any other software that we have previously used, assisting on complex projects and allowing for customisation. What’s more, it is frequently updated and improved.” One of the many benefits of Tekla Structures, the 3D construction modelling software, is that it allows for the design and planning of all building elements within the one model, ensuring that all information and data is consistent, amalgamated and easily accessible. This aspect of the software was particularly beneficial to Intelligent Steel, adds Crystal. “As a result of both cold and hot-rolled steel being specified on the project, and due to the fabrication of each differing

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The Vita Student Westgate project also presented Intelligent Steel with various unique and complex constraints. In addition to the tight time schedule, there were many site limitations. As well as an existing building situated in close proximity and a number of local businesses, the site was surrounded by two main roads that remained open at all times and supported Newcastle’s main bus routes. These challenges resulted in tight access, as well as vehicle and time restrictions, all of which rendered traditional construction methods unfeasible. “As a result, the scheme needed a building solution that would deliver both pace and innovation – hence our employment of modern methods of construction,” says Crystal. “We phased the different elements, such as the external and internal walls and floors, and then we lotted the delivery phases based on the schedule provided, all by using Tekla Structures. The software enabled us to release design data into the fabrication process in conjunction with the delivery programme, meaning that the correct components were delivered to site at the right time, ready for installation. Erection can also be scaled and accelerated throughout the build process and the model is vital to allow this to be planned in a sensible manner.”


DIGITAL DESIGN

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2 Furthermore, by using both Tekla Structures and the Howick extension, Intelligent Steel was able to export NC files directly from the model to the fabrication machines, increasing the speed, efficiency and accuracy of the project and fabrication process. The steel-framing machines were able to accurately place all punching and fixing holes, which not only allowed for the frames and trusses to be manufactured with extreme precision but also enabled the frame to be self-locating and jigging, reducing the build-time on site. This direct link between the Tekla model and the fabrication process also helped to vastly reduce the amount of construction waste produced, as

Crystal explains: “Only the specified quantities of material and building elements required for construction were manufactured. In the light gauge steel frame (LGSF) form of the building, the walls are load-bearing so the external walls were provided in a pre-boarded form. By using the direct link to the machinery from the Tekla model, we were able to save both time and material, resulting in a leaner production process”. Able to work with all materials, including steel, rebar and precast concrete, Tekla Structures is suitable for even the most complex of structures. Models created using Trimble’s software have the benefits of automatic clash detection, helping

to reduce the effects of human error and protect against costly rework later on site, as well as encouraging a streamlined collaborative approach, with multiple team members able to view and work on the same model at the same time. What’s more, once created, the data within the model can be used at every stage of a construction project, from the fabrication of individual building elements to managing the transportation and delivery of materials to site and the planning of optimum erection sequences and crane locations. Intelligent Steel won the commercial category for the UK Tekla BIM 2017 Awards with its Vita Student Westgate project. For more information about Trimble’s software, please visit: www.tekla.com/uk/solutions Images: 01-04. The Vita Student Westgate project used Tekla software to create a hugely successful building. Courtesy Intelligent Steel Solutions

COME AND VISIT THE INTELLIGENT STEEL AND TEKLA TEAMS AT OFFSITE EXPO

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COMPONENT INNOVATION

FINDING THE RIGHT FIXING SOLUTION! Stocked and serviced in the UK for more than 25 years, Aptus Fastener Systems have developed the most comprehensive range of innovative fastening solutions for modern methods of offsite construction. We stock and distribute a broad range of industrial fasteners and associated components to meet the structural design parameters for timber buildings under Eurocode 5. Whether you are constructing within panelised methods - timber frame and structural insulated panels (SIPS), volumetric construction techniques, crosslaminated (x-lam), and glue laminated (glulam) technology or hybrid applications, together with long term German manufacturing partners Heco Schrauben and Pitzl, Aptus Fastener Systems will have a solution that suits your needs.

Our fastener experts consider product line assembly and site assembly methods and can always find the right fastener solution, taking into account cost and performance. Our comprehensive range of products and services has been developed with modern sustainable building technologies in mind. We have recognised that as new construction methods emerge, our range of fasteners must keep pace, so we have developed a specialist range of ETA approved innovative fasteners from market leading manufacturers across Europe and beyond.

We supply our product range with an extraordinary level of service at every point of contact with our customers, and provide ongoing technical support to ensure that the right fastening solution is specified in the right application using the correct equipment. In partnership with your engineers, our technical support extends to installation guidelines, thread geometry, fastener surface finishes and design guidance. Working with our supply partners, Heco and Pitzl we can support both the manufacturer offsite and the professional onsite. For more information visit: www.aptusfasteners.co.uk or come to our stand B17 at Offsite Expo.

VISIT APTUS AT OFFSITE EXPO

SU

PP STO OR CK TE ED DI & NT HE U

Aptus Fastener Systems have developed the most comprehensive range of certified fastening solutions for the modular housing market.

Power Clamp – lifting device for transportation of solid panels and beams. HECO-Topix Countersunk & Flange Head – German innovated CE compliant structural screws through ETA. Pitzl Connectors – certified wood connection systems manufactured according to the highest quality “Made in Germany”

CALL NOW

FOR OUR LATEST BROCHURE T: 01773 740410 E: sales@aptusfasteners.co.uk @aptusfasteners

www.aptusfasteners.co.uk

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Metsä Wood’s Kerto® LVL (laminated veneer lumber) is so light that it reduces both traffic and transportation costs.

Visit us at stand E6 at Offsite Expo on 24th-25th September, or find out more at: www.metsawood.com


ARV OFFSITE SALARY GUIDE

KNOW YOUR WORTH Each year the team of expert recruiters at ARV Solutions get together to put together the Offsite Salary Guide. What’s inside the latest edition that you will find included with this issue of Offsite magazine? for growth. Within the industry we need to be sure that the workforce and talent is there to meet demands and build on the opportunities for growth. Is our salary guide reflective of your business? Are you struggling to find the talent to grow despite keeping salary offerings on par with competitors? In order for new talent to be interested in the industry, competitive salaries need to be offered as well as additional benefits and perks. These do not necessarily have to have huge financial implications. In our recent candidate poll we asked them to pick their top five benefits or perks, which would affect whether or not they would apply for or accept a job offer – it’s a candidate lead market after all. The Top Five were: 1. Competitive salary 2. Sense of purpose/job satisfaction 3. Culture – the office environment 4. Work-Life balance 5. Flexible working.

The Guide – now in its third year – is based on actual candidate placements throughout the year within the offsite construction sector. Salaries are likely to more closely reflect the figure people are moving jobs for (which is the figure we have to work with as recruiters) rather than that which people are earning within their role.

not exceeding higher levels, now sit within the top level. In addition, and although a smaller group, the bulk of the rest are within the lower levels – in previous years we have seen salaries evenly spread across the range.

Perhaps surprisingly, considering the shortage of skills along with the progression of the market, on the surface salaries look to have not increased significantly. Unlike previous years, broadly the salary bands look to have remained the same as in 2018. A deeper investigation is needed to understand the full story.

Without a doubt there will be a lot of change and indeed further opportunities for growth within this industry. Offsite construction will face many opportunities and challenges over the next 12 months.

Taking a closer look, we discovered there has been movement in that a far higher proportion of salaries, although 94

So what do we expect over the next 12 months?

Potential changes caused by political forces, alongside advances within the sector and huge backing from the government means offsite will certainly, regardless of political or economic ambiguity have opportunity

WWW.OFFSITEMAGAZINE.CO.UK | JULY/AUGUST 2019

Training and an easy commute were very close behind. It is imperative to look at the whole package on offer to a candidate. To most a good worklife balance and favourable office environment are just as significant as a competitive salary. We value feedback, it is important to us at ARV Solutions to ‘add real value’ to everything we do. If you would like to discuss our salary guide or any of our other services including project recruiting, benchmarking salaries, succession planning or competencybased interview questions contact us at: info@arvsolutions.co.uk or call 0117 959 2008. For more information visit: www.arvsolutions.co.uk

The ARV Solutions team will be on hand to discuss the Offsite Salary Guide at OFFSITE EXPO in September.


0117 959 2008 | www.arvsolutions.co.uk | info@arvsolutions.co.uk

With a huge passion for the construction industry, we are the UK’s leading recruitment consultancy for the offsite sector and it’s supply chain.

Call today for confidential advice on your career

• Exclusive vacancies • Permanent | Contract | Executive Search • Consultants who are experts in their field • We work with award winning companies from market leaders to start ups

Register your Register yourCV CVat: at: www.arvsolutions.co.uk/register www.arvsolutions.co.uk/register

@arvsolutions


OFFSITE EXPO PROFILES Offsite Expo 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. Here is a sample of companies that will be at the Ricoh Arena in Coventry on 24 & 25 September 2019...

Our Gebrik Brick Cladding System consists of approx 700 different natural clay brick slips, in a range of sizes, cast in polyurethane under factory controlled conditions. Non loadbearing, lightweight stretcher, stack or flemish bond panels are produced to create approx 1m² ‘sheets’ which can be screwed directly to either masonry, timber or steel frame substrates on site. With a full range of factoryproduced or site-applied components to suit external corners, surrounds to window or door openings and any other abutments, the system can cater for most architectural designs. For more information visit: www.aquariancladding.co.uk

Buteline designs, engineers and manufactures a world acclaimed plumbing system for hot and cold potable water, chilled water, central heating and underfloor heating. Buteline is one of the UK’s leading plumbing systems for the offsite and modular market, due to its quick and simple pressing process and its space saving, component & ‘O’ Ring free slimline fittings. It creates the most secure leak free joint, completely removing the risk of leaks in confined and inaccessible places. For more information visit: www.buteline.com/uk STAND NO: Z28

STAND NO: C20

FastClad is a UK manufactured brick slip cladding system, BBA Certified for a 50 year minimum service life. Suitable for both new-build and refurbishment, FastClad is manufactured using real brick which makes it ideal for use alongside traditional masonry, replicating different bond patterns and various face format sizes. FastClad enables the masonry skin to be taken off the critical path of the build, is up to four times faster to install than brickwork, less weather dependant, a third of the weight and can be installed both on site or in factory conditions. For more information visit: www.fastclad.co.uk

For more information visit: www.dutypoint.com STAND NO: C14

Flowdrill offer a cost effective and reliable alternative to welded nuts, insert nuts, welded bosses and hollow bolts in steel structures. Using conventional machinery, pillar drills, CNC’s etc. Flowdrill create increased material thicknesses which when tapped give consistent strong connections that cannot spin or fall out and with our standard tool create no swarf. Material thicknesses from 0.5mm to 10mm and diameters from M2 to M30 in steel, stainless steel, aluminium etc. For more information visit: www.flowdrill.com STAND NO: Z50

STAND NO: Z60

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Dutypoint Systems is an innovative manufacturer of fluid systems, including premium quality water pressure booster sets, innovative combined pump and tank systems, pressurisation units, electromagnetic water conditioners, heat interface units, packaged pump systems, as well as a myriad of associated products. Dutypoint Systems benefits from a wealth of expertise and knowledge built up over many years in the industry, combined with an impressive buying power, enabling the company to offer products with the best possible components at reasonable prices.

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GROHE is a global leader in premium bathroom and kitchen fittings, including showers, taps, toilet systems, ceramics as well as digital and professional product offerings. All GROHE products are developed with the brand’s core values in mind; innovative technology, sustainable credentials and superior quality and design. GROHE is renowned for its forward-thinking and premium product design which can be measured by more than 300 design accolades being awarded to the brand in the last ten years. For more information visit: www.grohe.co.uk STAND NO: A2


OFFSITE EXPO PROFILES For full details of exhibition and sponsorship opportunities at Offsite Expo contact: Julie Williams - julie.williams@radar-communications.co.uk or call 01743 290042

HEAT³ is custom-made shrink wrap transportation bags manufacturer, delivering packaging solutions around the world. HEAT³ shrink wrap bags minimise significantly time used for packaging modular units offsite and unpacking onsite. Perfectly fitting bags minimise modules manufacturers factory packaging waste up to zero. Bags themselves are also recyclable. HEAT³ shrink wrap bags helps to standardise your packaging procedures, so minimising all risks concerning protecting modules during transportation and storage. Size doesn’t matter – the bigger the better! Location doesn’t matter – bags can be shipped to your sites everywhere!

Ellis is a 200-strong team of creative, passionate and skilled people, providing design-led interior solutions for kitchen, bedroom, bathroom and loose furniture projects. Based in West Yorkshire, we have teams in place to manage every part of your project from design consultation through to installation and after-care, including everything in-between, and we cover the entire UK. For more information visit: www.jtellis.co.uk STAND NO: D18

Kingspan is a market leading manufacturer of premium and high performance rigid insulation products, and insulated systems for building service applications. Timber is traditionally the most widely used building material in the world as it is natural, easy to handle as well as bringing flexibility to design. Structural Insulated Panel (SIP) technology is the next generation of timber based construction. For more information visit: www.kingspan.com/group STAND NO: E5

For more information visit: www.heat3.eu/bags/ STAND NO: D19

LABC brings together all the building control expertise, skills and resources from over 3,500 professionals working across every local authority in England and Wales. LABC works with homeowners, designers, professionals in construction and manufacturers to ensure building projects achieve the standards defined in the building regulations. They also have a network of over 3,500 professional surveyors that provides clients with fast, impartial and expert advice. Whatever your position whether it be a homeowner, architect, contractor or any other professional, LABC will work with you to ensure your buildings are safe, healthy, inclusive and efficient. For more information visit: www.labc.co.uk STAND NO: G9

Lucideon’s knowledge and experience of the construction industry is backed up by multifaceted testing, consultancy and R&D capabilities. We work throughout the lifecycle of clients’ products, systems and buildings, from developing new materials and laboratory testing, to factory production control and on-site investigations. For offsite and modular buildings, we can help at all stages of the design and construction process, from materials selection and manufacturing, to installation and verification. Our integrated solutions combine multiple disciplines to create a comprehensive and unified solution. For more information visit: www.lucideon.com/offsite-expo STAND NO: G5

Modular Building Automation BV designs and manufactures equipment for the offsite construction industry worldwide. Specialising in timber frame, steel frame and SIP construction of frames, elements and volumetric methods, the company is well placed to support this growing sector with automation equipment. With our production facilities in the Netherlands, from where our equipment is designed and manufactured; our sales, distribution and technical support offices in the UK; and our worldwide network of dealers, the company can provide individual machines, production lines through to complete modular factory installations. For more information visit: www.modularbuildingautomation.eu STAND NO: Z30

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OFFSITE EXPO PROFILES

At Metrotile we often emphasise the importance of our roofing’s many benefits, the core of which is the unsurpassed strength and low weight offered by the highest drawing grade steel our tiles are pressed from. The low weight – just one seventh of so-called traditional roof tiles such as slate or clay – of each Metrotile profile is ideal for factory-built modular housing as it helps to keep the overall weight down during the transportation process and places significantly less pressure on the supporting frame and foundations without compromising security or aesthetics. For more information visit: www.metrotile.co.uk STAND NO: A8

Peter Dann are an award-winning engineering consultancy who specialise in structural and civil design. They offer a broad range of services within the construction industry, covering all sectors including commercial, education, industrial, hotel and leisure, medical, residential, restoration, civil and retail. Peter Dann is a sustainable design practice, working toward green initiatives on all of their projects where viable. With over 50 years’ experience, the company aims to always exceed their client’s requirements through dynamic, efficient and economical civil and structural solutions for the built environment. For more information visit: www.peterdann.com STAND NO: Z40

Innovation and sustainability form part of our core values. As a result Tilcor has grown to become a major player in the supply of lightweight pressed metal roofing tiles around the world. A constant dedication to lifting the industry standard in product design, quality manufacturing and competitiveness has earned us an international reputation for excellence. With our metal roof tiles now installed in over 80 countries and proven in some of the most extreme weather conditions, Tilcor’s products exceed every common benchmark for strength and durability.

Vertex Systems provide professional BIM software for wood and steel framing that automates design and manufacturing processes. Vertex BD automates the process of generating architectural drawings sets, panel fabrication drawings, structural layouts, cut lists, material reports and manufacturing data, all from the BIM model. For more information visit: www.vertexcad.com STAND NO: E20

For more information visit: www.tilcor.com STAND NO: G14

Protect provide a comprehensive range of construction membranes, roofing membranes and roofing accessories. The construction range includes vapour permeable wall membranes including enhanced thermal performance solutions, vapour control and air barriers also with enhanced thermal performance solutions and a range of sealing tapes and other accessories to provide a one stop shop for all requirements. The roofing range includes vapour permeable and vapour impermeable underlays in a range of weights and strengths depending upon the application. For more information visit: www.buildingproductdesign.com STAND NO: G7

Wetherby Building Systems are the UK’s market leader in the design and supply of a wide range of solid wall insulation (SWI) systems, decorative render and brick slip finishes for the modular and offsite construction market. Wetherby’s innovative systems are compatible with a wide range of modern methods of construction, offering attractive, yet environmentally sympathetic façade solutions that have been successfully installed on many new build schemes, including domestic homes, commercial buildings and educational establishments for over 20 years. For more information visit: www.wbs-ltd.co.uk STAND NO: D16

FULL OFFSITE EXPO EXHIBITOR LISTING IS AVAILABLE ONLINE AT WWW.OFFSITE-EXPO.CO.UK

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STEEL – THE OPTIMUM OFFSITE SOLUTION ADAPTABLE I RIGID I ROBUST I NON-COMBUSTIBLE

DESIGN SUPPORT Offering unparalleled levels of support – our highly qualified technical design team establish the m  ost effective and cost-efficient solution. All drawings are passed through the client’s approval p rocesses before work can begin onsite.

OFFSITE MANUFACTURING The expansion of the EOS advanced manufacturing facility together with the development of a new fabrication plant supports our market leading all-inclusive pricing initiative.

COST CERTAINTY With a dedicated in-house e stimating team, EOS guarantee a competitive pricing structure, w  ith no hidden costs. We can provide a lump sum total price package which will not alter, providing the specification remains unchanged.

CONTINUOUS COLLABORATION EOS operatives offer technical a dvice and installation training. Installer teams can benefit from our ‘Tool Box Talks’ and phased site visits to offer independent quality checks.

With expertise in panelised, volumetric modular and pod technology - EOS specialise in the design, manufacture and supply of a wide range of light gauge steel framing systems (LGSF) for the offsite markets.


Embracing a world-class manufacturing ethos and optimising design for manufacture and assembly (DfMA) principles - EOS invest in research and development to bring new and innovative products to market. COME AND MEET THE TEAM AT OFFSITE EXPO STAND G17 ON 24-25 SEPTEMBER AT THE RICOH ARENA, COVENTRY.

Volumetric Modular Pod Technology

Stud & Track

Facade Panels

www.eos-facades.co.uk

Roofing & Flooring Systems

SFS Infill

Load-bearing Systems


FFSITE

EXP

RICOH ARENA - COVENTRY CONSTRUCTION

TECHNOLOGY

INNOVATION

CALLING ALL CONSTRUCTION PROFESSIONALS! ARE YOU LOOKING FOR THE LATEST OFFSITE INNOVATIONS?

The brainchild of leading industry experts who understand the urgent need for a dedicated event OFFSITE EXPO will feature a combination of advanced offsite manufacturing approaches and smart digital technologies that are transforming the way buildings are designed and constructed. OFFSITE EXPO provides the ideal forum for construction professionals looking to engage with key offsite industry contacts, network in vibrant surroundings and acquire new knowledge - all completely FREE!

• FREE to visit • Over 3,000 targeted construction professionals attending • Dedicated Offsite Connect Buyers and Specifiers Forum with over 100 companies signed-up • Custom-built features and Live Demo’s • 100 Offsite manufacturers and suppliers available to meet one-to-one • Over 100 speakers in the Explore Offsite CPD Masterclasses • 10 Countries represented in the international Offsite Summit • Free consultations with our ‘Ask the Offsite Expert’ team

Register FREE to attend at WWW.OFFSITE-EXPO.CO.UK/BOOK SUPPORTED BY: HOUSING

Profile for Radar Communications

Offsite Magazine - Issue 18 (July/August)  

Offsite Construction Magazine - focusing on UK and International construction and buildings

Offsite Magazine - Issue 18 (July/August)  

Offsite Construction Magazine - focusing on UK and International construction and buildings