Designing New Forms with Light Steel Frame

The construction of 504 Bristol Rd was a complex project due to the location of the site and the design’s unusual architectural shapes and forms. The perfect solution was the lightweight steel frame Hadley Steel Framing System (HSF).

504 Bristol Rd is a brand-new development located in Selly Oak, Birmingham, consisting of offices, retail and multi-level student accommodation of 70 self-contained luxury studios and has various internal and external communal spaces including study pods and a large courtyard.

The shape and design of the building in this project make it unique and innovative. The building was designed with reference to the historical character of the site and with respect to shipbuilding. This is clearly translated in its built form, massing and the materials used. The 3,193sq m space is arranged over four floors, with the ground floor given over for retail purposes, and the fifth floor largely glazed and setback. The design for this scheme was very exciting as the challenge faced was to provide a building of an architectural merit that was equal to the existing Victorian building that occupied the site.

The inverted and skewed brickwork and window detailing is derived from an inverted traditional Victorian bay window. The layering also takes a strong cue from the Victorian layering and articulation of façade treatment with vertical and horizontal alignments. The conical form turning the corner was inspired by vessel building which happened near the site. The internal layout of the studios is to allow students, an open plan and independent space. The development has good standards of natural light and ventilation. Window sizes are larger than traditional residential housing to allow increased daylight levels and maximise passive solar gains. The development has led to a significant and material improvement in the appearance of the site and the street scene by virtue of its modern, contemporary design and the use of quality materials.

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Considering the highly restricted access and time constraints, the design team concluded that the best construction method for this development would be a hot rolled steel frame on the ground floor supporting a ComFlor® transfer deck to take four floors of cold rolled structural load bearing steel frame system such as HSF.

Hadley Steel Framing as a manufacturer wanted to prove and demonstrate that the conical form can be built utilising their system and offsite construction techniques. As steel is such a versatile construction material, it was able to produce a unique and innovative shape and

design while at the same time create a structure that is both durable and safe utilising the expertise and skills of HSF.

Due to Hadley Steel Framing’s unique manufacturing methods, cold roll forming, they could produce the frames with efficient production solutions, reducing design and manufacturing time whilst simultaneously ensuring outstanding quality and accuracy. These construction components can be of bespoke design or standardised components offering the opportunity for creativity and efficient construction best suited to the project criteria.

Using the lightweight steel frame structure meant the project was delivered on time, on budget whilst maintaining the highest quality standards. The challenging site, with minimal storage demanded a meticulous delivery schedule and by using this offsite method, delays were avoided in the final project delivery. Costs were easier to predict, as design specifications were met reducing the margin of error and lowering the cost of remedying possible construction defects.

By using HSF, solutions could be created that met the design requirements and time scales ensuring

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a seamless process to completion. All structural calculations were made ensuring all structural components for the whole building frame (composite floor slabs and structural steel) were designed efficiently thus working within the project’s financial constraints. One other benefit was to provide the client and contractor with a building that was watertight within three weeks, which allowed them to commence internal building work whilst brickwork and rainscreen cladding was installed at the same time.

Hadley Steel Framing had not undertaken such complex shapes such as the conical design before and the result is hugely successful and a credit to the project teamwork. It is equally a striking addition to what has been for many years a tired and deteriorating urban street scene in Selly Oak. The 504 Bristol Road development provides a new level of much-needed contemporary student accommodation within the student village of Selly Oak providing all the necessary facilities on-site and creating a luxurious environment for students to thrive.

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For more information visit:

www.masarchitecture.co.uk www.hadleysteelframing.com

Images:

01-04. Using the lightweight steel frame structure meant the project was delivered on time, on budget whilst maintaining the highest quality standards. Courtesy MAS Architecture/Hadley Steel Framing

FULLY TESTED AND CERTIFIED SOLUTIONS

Architects and developers are under increased pressure to design safer residential buildings that deliver predictable performance. Steve Thompson, Managing Director for light steel framing specialists EOS makes a strong case for robust testing and certification.

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The Hackitt report highlights the failings within the construction industry and sets out recommendations for a major shakeup of the current regulatory framework governing building control and fire safety in residential buildings.

Our products, processes and whole business philosophy show that as a manufacturer, we take our responsibilities extremely seriously. At the heart of this is rigorous testing, technically competent people and a systems approach to our solutions.

Information and record-keeping around construction projects is often fragmented – I believe ‘the golden thread’ is a step towards true transparency. Building Information Modelling (BIM) is now acknowledged as crucial in the design and construction process, but it goes beyond that – it provides a significant and lasting legacy of digital information from all those involved.

EOS operate to BIM Level 2 and this technology is seen as fundamental to not only our business operation but how we collaborate with our construction partners. In addition to BIM, with our Etex group partners we consider taking a systems approach,

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as recommended in the Hackitt report – backed by rigorous testing regimes and certification is also a critical factor in determining building performance and safety across the medium to highrise residential sectors.

As part of Etex, together with Group partners – Siniat, Promat and FSi – we have invested considerable time and research in developing a range of non-combustible walling and flooring systems. We are committed to technical excellence and understand the challenges faced by architects and through Etex Group, have some of the best fire experts in the UK on our team. Up until now there has been a lack of a systems-based approach to eradicate the pitfalls surrounding specification decisions.

Predictable Performance

By eliminating uncertainty through rigorous testing regimes, EOS deliver light steel frame systems with certified and predictable performance. Recently presented with Best External Product at the 2021 Housebuilder Product Awards, Thrubuild® is an all-in-one non-combustible certified system exploiting the latest products, technical know-how and manufacturing excellence of the combined Etex team. Providing crucial safety, time and cost benefits, the Thrubuild® range has multiple loadbearing applications for low and medium rise developments and can be used for external or internal walls together with internal and separating floors.

In addition to the Thrubuild® loadbearing range, we have researched and developed Thruwall® – a fully engineered custom-designed non-loadbearing infill system manufactured offsite and supplied as a certified kit of parts that can be used with concrete and steel main frames.

Following the outstanding success of Thruwall®, EOS has taken factory prefabrication and preassembly to another level. Developed and rigorously tested, pre-assembled frames (PAF) are an evolution of Thruwall® which are delivered to site as a unitised non-loadbearing infill system encapsulating light steel framing and external sheathing.

All components and products in the Thrubuild®, Thruwall® and PAF system range have been rigorously tested together for fire, acoustic, weathering, airtightness, durability and mechanical performance. Fire resistance periods of 60, 90 and 120 minutes are achievable. When walling and flooring systems are built with Etex Group components and materials, following a validation process — Etex award a 30-year warranty.

For more information visit the EOS information centre: www.eosframing.co.uk/information-centre

Images:

01. Riverside Quarter, the first development in the

UK to specify EOS’s PAF System 02. Horizontal rig for structural testing at Etex’s

Innovation and Technical Centre

STEEL REUSE: SHIFTING FOCUS

As we decarbonise construction in line with the UK’s net zero 2050 targets, attention is turning to the challenges of moving to a more circular economy. Michael Sansom, Associate Director, Steel Construction Institute (SCI), outlines how a new website portal could help the steel sector.

Steel construction systems are already highly circular, benefitting from steel’s intrinsic ability to be recycled, again and again, without loss of properties. For example, current endof-life recovery and recycling rates for structural steel in the UK is >95%. The challenge for the steel construction sector therefore is how to move from recycling to reuse.

A new initiative by the SCI will facilitate the reuse of structural steelwork through the collection and aggregation of data on new and reclaimed structural steel products – we are also assessing how this could be adopted and applied to the light gauge steel sector.

SCI has developed a prototype website portal for collecting and sharing information about steel reuse and for trading reclaimed steel structures and components. In terms of the functionality of the portal, it has been developed to address both: • Reuse today scenario, i.e. a traditional ‘sell-buy’ exchange but devoted specifically to reclaimed structural steel • Development of a database of new structural steel in newly constructed buildings, i.e. facilitating future deconstruction and reuse.

Both of these scenarios contribute to a circular economy and can substantially reduce environmental impacts. Not only are the production impacts of making new steel avoided but by reconditioning and reusing reclaimed sections in the UK, the transport impacts of importing new steel and exporting steel scrap are avoided. Currently the UK exports around 75% of steel scrap for recycling overseas. Studies suggest that greenhouse gas emission savings of around 95-97% are achievable through reuse compared to primary steel production.

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There are also potential economic benefits. Although new steel and scrap steel prices fluctuate, a review of the price differential between new and scrap structural steel between 2002 and 2018, shows an average price differential of £313 per tonne. This represents the potential profit opportunity of reusing, as opposed to recycling, steel sections. There are also many case studies of whole structure reuse where significant cost savings were achieved relative to using new steel.

In terms of reuse today, the prototype portal enables sellers and buyers to make contact and exchange information both pre and postdemolition. Pre-demolition building information provided includes:

• Age of building • Scheduled demolition date • Size of building • Overview of section sizes, grade, sub-grade, etc. • Contact details to enquire about the building.

Post-demolition it is assumed that the building has been deconstructed with a view to reusing the reclaimed members, i.e. care has been taken to deconstruct the building carefully with a view to preserving the structural steel members. Post-demolition, more information is readily available, for example, section designation, length, etc. If testing is required, the results should also be made available.

Buyers can search the database of available reclaimed sections using the following search criteria:

• Section type; e.g. UB, UC, PFC • Postcode and search radius • Section size from a dropdown menu of standard section sizes.

To facilitate future reuse, the portal captures and stores detailed information on new steel buildings to enable them to be refurbished, extended and potentially reused in the future. Data fields relate to building or project information plus elemental information.

Project information is inputted manually and elemental or product information is provided electronically to the portal via uploaded IFC files of the erected structure. The whole building structural models are held confidentially and securely until such point as they either due to be refurbished, structurally extended or when they are scheduled for demolition. At this time, the building information becomes searchable via the portal and the elemental information will be placed in the database of reclaimed sections and made available for purchase. Over time, this database will grow to provide a virtual stock of steel elements with all associated properties and provenance, to facilitate mainstream reuse.

Because of the factory-based nature of structural steel and the widespread use of BIM by the sector, the product information required to facilitate future reuse is readily available and it is simply a matter of collecting, storing and retrieving this information effectively. As a minimum, the following information is to be stored in the database for each structural element:

• Section designation, length and weight • Steel grade and sub-grade • Product and execution standard • Mill certificate • Environmental product declaration (EPD).

To date, development of the prototype reuse portal has focused on hot-rolled structural steelwork; these members being durable, dimensionally stable and importantly robust. Consequently, they offer the greatest potential for reclamation and reuse. Light steel structural elements including 2D (panels) and 3D (modules) are highly reusable, and we need to start collecting and storing the relevant properties, as described above for hotrolled sections.

There are other aspects relating to the reuse of light steel systems that also need to be explored such as how we can standardise our systems to facilitate reuse. It is time for all of us to think about our carbon footprint, both personally and professionally, and proactively think about what steps we can take to help tackle the ongoing climate emergency.

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A new initiative by the SCI will facilitate the reuse of structural steelwork through the collection and aggregation of data on new and reclaimed structural steel products – we are also assessing how this could be adopted and applied to the light gauge steel sector.

For more information visit:

www.steel-sci.com

Images:

01-03. Steel is highly recyclable and a perfect circular material providing the structure of many offsite buildings

HOUSING PROJECTS NEED A CLEAR VISION

A new guide from The Housing Forum offers practical guidance for housing associations and councils on procurement which can be applied to offsite construction. The key is to start with a clear vision and then hold on to it, says its author Matthew Goulcher, Managing Director of Levitt Bernstein.

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While the housing sector has much to be proud of, all of us who’ve been involved in the design and construction of new homes know what a frustrating business it can be. The all-too-common approach has been to opt for the cheapest bid and then transfer as much risk as possible to the contractor. As sure as night follows day, corners get cut and quality invariably suffers. Many well-meaning initiatives intended to rectify this flaw have not proved lasting, for a variety of reasons.

This time it may be different. The quality failures that have come to light across many housing schemes, and tragically in the Grenfell Tower disaster, have galvanised unprecedented determination from industry and government to overhaul quality and safety. At the heart of the new mindset is an acceptance that an improved procurement process is essential to the reforms. Government has made valueled procurement a policy imperative in its procurement green paper and an important strand in its ‘Construction Playbook’ – a blueprint for the development of the construction industry.

The Housing Forum, whose members span the housing spectrum – from clients to contractors, to manufacturers and designers – has been using its expertise to capture good practice. For the past 18 months I’ve been chairing a working group which has been examining procurement processes over the last 25 years and reflecting on what has worked, and what hasn't. It’s a complex picture. There has been a great deal of blame for failure channelled at design and build contracts, for example. But what has become apparent from our workshops is that even with design and build, good teams working well together with a supportive client, and an excellent contractor team that really wants to engage, can produce excellent projects. However, in the current environment this is achieved more by luck than any sort of planned process, so The Housing Forum has set out the key ingredients for success.

The result is ‘Better Procurement for Better Homes’ a very practical guide for local authorities and housing associations, to help them get the developments they aspire to and build the sustainable communities that they and their residents want. The guide is about establishing and maintaining good relationships, having a clear vision and holding on to it. And managing project costs and risks equitably. We are also advocating bringing in the supply chain early – which will help for adopting homes built offsite too.

It’s split into six chapters and covers all the various steps from design considerations, through to achieving quality on site and the contracts underpinning the collaborative approach we recommend.

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We are not being prescriptive – but rather, setting out a methodology to help clients articulate a vision and show them how to work with the best people to deliver that, including harnessing modern methods of construction (MMC). The guide makes the point that long-term construction quality can be improved within a controlled factory setting. Here are some of our key recommendations:

Create a vision – we're recommending all projects should have a formally documented project vision plan – and we’ve developed a template for clients tailored for this. The areas that this should encompass are broad: how you intend to maintain the vision with good project governance and monitoring? What are your cost and programme parameters? How do you intend to form the team – and deliver design quality? What is the social value you want to lever from the project and how do you draw in the voice of the residents? These are just some of the considerations to work through at this early stage.

Appoint the right leader – our second non-negotiable for success is about getting the leadership, right and getting the project setup set up properly in relation to governance, advocacy and client ownership. We're talking here about holding on to a concept vision through its life. And that needs high-level leadership from inside the client organisation.

This is often how it works in the higher education sector where we also do a lot of work. For example, the estate’s development department deliver a project. But there will also be a steering group of academics and other end users. If they see they're not getting the lab that they wanted, or the reception they wanted, they shout, and there's not enough of that that goes on in housing.

Foster collaboration and procure

on shared values – be clear about your vision and objectives, including defining ‘quality’, and procure the team based on a shared understanding and alignment of values. Have clear selection criteria, including a price evaluation model that does not promote a ‘race to the bottom’. It’s important too that these shared values should be embodied throughout the supply chain and not stop at first tier contractors.

Drive quality of design with a clear

design brief – procuring good design on projects must start with a clear and realistic design vision setting the degree of aspiration, which is endorsed at senior level, and setting out how you intend to provide continuity of the team to provide design integrity and the golden thread.

Appoint the consultants and

contractors early – early appointment of the consultant team and contractor and early engagement with key suppliers is crucial to drive quality, innovation and collaboration and greater cost certainty. It is important to select a form of contract which allows for early appointment and a process for developing design and price collaboratively.

Put in place a clear inspection regime

– it needs to be clear on-site who's doing what. Our view is that the design team needs to be involved more – they are in the best position to know whether what was designed has been built. Good procurement can never be about signing a design and build contract and just turning up at a monthly meeting: it’s not about selecting contractors on the lowest bid and nor is it anything to do with finding as many ways as possible to offload risks on to the supply chain. All those things are a recipe for cost overruns, disputes and defects, as many housing providers have learnt the hard way. The values and behaviours set out in our guide founded on collaboration between client, consultants and contractors will result in safer, higherquality homes and better places to live.

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

You can download the report at https://bit.ly/30obbfc

Images:

01. ‘ Better Procurement for Better Homes’ sets out a series of guidelines for improving design and construction quality, avoiding costly mistakes and managing risks 02-03. Housing is undergoing a revolution with offsite manufacture playing a central role. Courtesy TopHat