Why Buy British Precast

MARCH 2017

UK offsite solutions Housing white paper Precast brings a lot to Response calls for resilient the table to offset risks homes and support for all of lightweight products manufacturers p15 p31

More housing, resilient housing Production is being increased to meet demand and deliver high performance Safe installation Support for project teams to meet CDM obligations from manufacturers

Sustainability Cradle to gate, and through life, manufacturers, designers and contractors have a role to play to deliver whole- WHY BUY life performance BRITISH PRECAST

Offsite From hidden groundworks to architectural staircases: local, durable, robust solutions Contents Reasons to Buy British Precast BRITISH 4 News The cement industry employs 2,000 people directly,Provides and 15,000 employment indirectly in mainly in rural UK rural areas areas Enhances and protects biodiversity AHMM wins concrete creativity award PRECAST 6 Sustainability: Working service life Almost ten years on from the government/industry sustainable

UK sourced How totex can help to deliver better whole-life value construction strategy, the construction sector still has much to Responsibly constituent sourced do. As product manufacturers, British Precast members are materials 8 Sustainability: EPDs British Precast’s Environmental Product Declarations playing their part by minimising impacts in manufacture and providing products that designers can use to create sustainable 10 Sustainability: BIM solutions. All members are signatories to our Sustainability LEXiCON offers consistent product data Charter. And to help designers, British Precast is launching Over 6,000 hectares of priority habitat has been created on restored sites EN15804-compliant Environmental Product Declarations this Over 80% of cement and 95% of aggregates are sourced from within the UK All British Precast members are signatories to our Sustainability Charter 12 Sustainability: SuDS spring (p8). Designers can play their part by considering The benefits of sustainable urban drainage systems working service life (p6) and overall impact of all products 14 Sustainability: Pipe bedding working together rather than products in isolation (p14). DURABLE FIRE RESISTANT ROBUST LONG LASTING EXCELLENT ACOUSTIC/THERMAL PROPERTIES How rigid pipes can deliver time and cost savings There is much talk of offsite solutions – as there was ten years The average travel distance from factory to site is only 70 miles ago. To deliver the increase in housing, we need the government Reduces imports and improves Local construction 15 Offsite: Mitigating risk the UK trade gap products to address planning (p30) and not to intervene in construction Why precast is the answer when adopting offsite methods. The government needs to ensure long-lasting housing 16 Associate members directory that is resilient to fire (p32), flood and overheating. Government A list of British Precast Associate Members should support all manufacturers to encourage investment in Buying British Precast Concrete all solutions. Masonry construction delivers the vast majority Reducing imports will help to sustain the UK •construction Supports industry a UK manufacturing sector and the UK economy 17 The timeless case for concrete of housing and if an increase in housing starts is to be achieved, • Protects the jobs and livelihood of UK society Environmental, social and economic there will need to be more masonry construction (p31). British • Reduces travel distances and protects our environment 18 Buyers guide Precast members also offer offsite solutions and the choice of Use our online Buyers Guide to choose your UK construction product precast can address many of the risks associated with British Precast Manufacturing Members and their products lightweight offsite solutions (p15). 20 Offsite: Modular retaining walls British Precast members are signatories to our Health and A domestic Precast Sector is essential for the UK Interlocking precast blocks tame a water course Safety charter. This includes a five-year commitment to a 65 per cent reduction in lost time incidents. But as responsible The products our industry manufactures of products imported from abroad [3]. Choosing Buy British Precast contribute to the UK construction industry British Precast means a shorter delivery time and 22 Offsite: Flooring manufacturers, their concerns extend beyond the factory gate. - improving our schools, houses, offices, lower carbon. The UK government’s 2025 construction targets Adventure centre case study They provide guidance for safe installation of their products hospitals, transport networks, utilities and refer to a 50% reduction in the trade gap (p27-29) which should be heeded by designers, contractors and quality of life. Responsibly sourced precast between exports and imports for construction 24 Offsite: Architectural and structural clients in fulfilling their CDM obligations. British Precast is part of the wider UK Mineral Responsible and ethical sourcing is easy to products and materials. Buying British Precast Two case studies showing precast in action will help to address this trade gap and reducing To find a responsible supplier of precast and masonry, Products Industry which directly contributed demonstrate for products made in the UK from 26 Offsite: Manhole systems to the UK economy by generating over £6.4bn UK sourced constituents. British Precast meets the import of construction products will help go no further than our buyers guide on p18 or online at in GVA in 2014, had a turnover of £20bn and this criteria. Look for BES 6001 certification on to enhance and sustain the UK construction A precast manhole system saves on concrete www.britishprecast.org/buyersguide. industry. contributed to £495bn turnover in industries construction products. 27 Installation: Pipe lifting Matthew Clay downstream of the supply chain. Managing Director, Bespoke Products All British Precast members are signatories to our Inherent Properties of Precast How a concrete pipe lifter contributes to site safety The UK Precast Sector has an annual turnover Sustainability Charter. Forterra Building Products Limited Precast Concrete has inherent benefits that of £1.3 billion [1] and directly employs 13,000 www.britishprecast.org/sustainabilitycharter 28 Installation: Paving President, British Precast people in the UK [2]. enable designers to deliver cost effective, Biodiversity and our rural economy materially efficient projects. NHSS30 raises the bar for modular paving British Precast is the trade association of precast concrete manufacturers and is a federation including specialist product groups and sector bodies. British Precast The concrete industry makes a significant Inherent benefits include: 29 Installation: Flooring www.britishprecast.org contribution to biodiversity and nature • non-combustible Precast concrete and concrete blocks are How to meet CDM obligations British Precast is affiliated to the Mineral Products Association (MPA), the trade association for the formed from three constituents: water, cement conservation through the management and • durable aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and silica sand industries. www.mineralproducts.org and aggregates. More than 80% of cement restoration of sites of mineral extraction. • robust 30 Housing: Delivering more is manufactured in the UK from UK sourced MPA data shows that over 6,000 hectares of EMAP British Precast • moisture resistant Small sites, new entrants and masonry Telephone House The Old Rectory materials. More than 95% of aggregates are priority habitat has been created to date on restored sites. • inert 69-77 Paul Street Main Street sourced from within the UK and typically close to 31 Housing: Response to white paper London EC2A 4NQ Glenfield the precast factory. With an abundant supply of limestone in the • rot resistant Masonry construction is part of the solution Email [email protected] Leicestershire UK, the manufacture of cement in the UK results • good thermal properties Printed in England by Headley Brothers Ltd LE3 8DG The average travel distance from precast factory An EMAP service – Powered by ASCENTIAL United Kingdom to project site is 70 miles - this equates to just a in a lower carbon footprint. The cement sector • good acoustic properties 32 Housing: Fire few hours’ drive compared to the longer journeys employs 2,000 people directly, and 15,000 Non-combustible materials mitigate the risk of fire Telephone: +44 (0) 116 232 5170 indirectly in mainly UK rural areas. [4] Find out more at www.britishprecast.org Email: [email protected] [1] Facts at a Glance, Mineral Products Association, 2016 33 Housing [2] Health and Safety Statistics, British Precast, 2016 [3] Sustainability Matters, British Precast, 2016 [4] Cementing the Future, MPA Cement, 2013 Precast upper floors, case studies and thermal bridging

www.britishprecast.org/buyersguide British Precast | 3 Contents Reasons to Buy British Precast BRITISH 4 News The cement industry employs 2,000 people directly,Provides and 15,000 employment indirectly in mainly in rural UK rural areas areas Enhances and protects biodiversity AHMM wins concrete creativity award PRECAST 6 Sustainability: Working service life Almost ten years on from the government/industry sustainable

Allford Hall Monaghan Morris (AHMM), a London-based architecture practice, is committed to making satisfying On Track to Higher Quality Concrete buildings that are beautiful and enjoyable to use. With an international portfolio, the company is recognised for its impressive work and strategic take on architectural design. Taking a design-focused and analytical approach towards architectural projects, AHMM has worked on a number of award-winning concrete developments, on a range of differing scales. Projects include: Walsall Bus Station (2000) with an elliptical in situ concrete canopy; Yellow Building (2008) in Notting Hill, which featured raking and education projects Dagenham Creativity in Concrete Award, in Burntwood School, London exposed concrete elements; Park School (2012) and the RIBA recognition of its inspiring and innovative offices at Tooley Stirling Prize-winning Burntwood innovative architectural concrete Street (2008); the Angel Building School (2014). design work. (2010) with its stunning entrance British Precast is delighted to of light and exposed concrete; present AHMM with the latest www.ahmm.co.uk • Measure total air content and temperature while mixing Increasing block production Offsite demonstration • Monitor real-time batch plant data with an iPhone app and dashboard reports • Manage mixes and make adjustments to optimize quality and This new facility opened in 2016 eciency and reduce out-of-spec concrete and produces blocks for 50 houses per day • ADVA® Cast high-range water reducing admixtures are specially

Manufacturers are reporting a doubling of block output to meet the formulated for the Precast/Prestressed Concrete Industry. forecast increase in housing starts and that spare capacity remains in the system. The block industry is increasing capacity through investment. Throughout the UK there was significant investment in 2016, and there GCP Applied Technologies, formerly Grace Construction Products, is further investment for 2017. This is in the form of replacement of old plant to increase production rates or new additional production lines. oers a full line of innovative products and technologies for the precast/prestressed concrete industry. Members also continue to extend working hours and bring Precast sandwich panels have been used for the external envelope with The GCP portfolio includes chemical admixtures, ﬁbers, and unique technologies such as AIRtrac™. mothballed production lines into operation to meet increasing demand, precast flooring for ground and internal upper floors for this pilot and they report that further spare capacity can be brought online as and detached house project by Creagh Concrete. External decorative finish gcpat.com/Precast when demand increases further. will be direct paint and hand laid stone in vernacular style. To speak with a GCP representative please call +44 (0)1925 855330 4 | 00British Month Precast 2012 www.cnplus.co.uk News AIRtrac™ AHMM wins concrete award ® Allford Hall Monaghan Morris is the British Precast Creativity in Concrete Award winner ADVA Cast

Manufacturers are reporting a doubling of block output to meet the formulated for the Precast/Prestressed Concrete Industry. forecast increase in housing starts and that spare capacity remains in the system. The block industry is increasing capacity through investment. Throughout the UK there was significant investment in 2016, and there GCP Applied Technologies, formerly Grace Construction Products, is further investment for 2017. This is in the form of replacement of old plant to increase production rates or new additional production lines. oers a full line of innovative products and technologies for the precast/prestressed concrete industry. Members also continue to extend working hours and bring Precast sandwich panels have been used for the external envelope with The GCP portfolio includes chemical admixtures, ﬁbers, and unique technologies such as AIRtrac™. mothballed production lines into operation to meet increasing demand, precast flooring for ground and internal upper floors for this pilot and they report that further spare capacity can be brought online as and detached house project by Creagh Concrete. External decorative finish gcpat.com/Precast when demand increases further. will be direct paint and hand laid stone in vernacular style. To speak with a GCP representative please call +44 (0)1925 855330 4 | 00British Month Precast 2012 www.cnplus.co.uk Sustainability: Working service life The whole picture Measuring costs on the basis of total expenditure – known as totex – can help to deliver better whole-life value

cross the built Specified Design Life Vs Working Service Life of Different Products environment there are many examples where it Ais short-sighted to solely consider capital expenditure without any consideration of DL Specified (SL) Product A (SL) SERVICE LIFE (SL) Product B operational costs and lifespan. DESIGN LIFE Precast products, including SERVICE LIFE concrete masonry, have

exceptional durability and this (DL) can offer distinct advantages to clients in sectors such as housing, education, transport, energy and water. It is from the last of these sectors that the issue is explored in detail below.

Working service life vs design life It is two years since the water Intervention level: rehabilitate / replace industry regulator Ofwat started performance Asset to measure water companies’ costs on the basis of total expenditure (also known as totex) rather than on capital and operating expenditure. The 50 100 150 200 250 300 Years argument for using precast concrete for pipeline systems has never been stronger. There has always been a moral Product A: SL/DL <2 case for choosing pipeline products with a long lifespan. However, in the past the historic capex bias has made it difficult to www.concretepipes.co.ukProduct B: SL/DL >2 defend a product designed to deliver an extended lifespan – albeit with a competitive capex perform adequately. Long design today would need to operate, on here is the length of time between cost compared with alternative and service life are the key average, for more than 800 years the “design life” and the “service pipe materials with a shorter or competitive advantages of according to Defra’s white paper life”. Any pipeline installed today unproven life expectancy. The service life of a pipe, or pipeline, without rehabilitation or particularly demanding if the concrete pipeline systems. Water for Life, which was will need to have a working Now, following the introduction is the length of time it can be replacement. This is not to be owner is accepting higher capex Rigid sewer systems, both clay published in December 2011. service life of several hundred within the UK water industry of expected to perform before its confused with design life, which costs in order to deliver lower and concrete, have been in Given this background, it would years, so it is worth considering Asset Management Plan (AMP) 6, performance falls below the original can be the period over which the (opex and) totex costs. The design service for more than a hundred be reasonable to expect water pipelines that can credibly claim and the focus on totex, asset design requirements without full financial depreciation is team must have confidence that years and we can draw on this companies and other sewer asset to achieve the longest serv ice life owners and specifiers are starting rehabilitation or replacement calculated for infrastructure the asset will perform as practical experience to ensure owners to be consistently at the lowest cost. to appreciate the benefits precast assets. predicted, usually by reference to that new systems will perform demanding products with a In the CPSA’s view, there has concrete pipelines can deliver. A big challenge for asset operational data for an Long design and even better. service life approaching this always been a moral case for A key aspect of totex is asset owners in demonstrating appropriate period of time. However, given the slow rate of timespan, yet speciﬁ cation choosing products with an management and getting the authentic totex savings on service life are the replacing and renovating the decisions are commonly being extended lifespan. As a sector maximum service life out of new installations is the need Long life key competitive existing wastewater pipework made on the basis of a design life producing highquality, durable assets. The service life of a pipe, or to make reliable forecasts on Large diameter concrete pipes are advantages of infrastructure in the UK, even a of just 50 to 125 years. product with proven longevity, we pipeline, is the length of time it the future performance of assets used in the construction of design life exceeding 100 years The deﬁ ned design life does not hope to see a continuation of the can be expected to perform before and the interventions required sewerage systems for new concrete pipeline may be insu cient in reality. mean that the products will cease move towards an authentic totex its performance falls below the in order to extend the service life developments and to replace systems If this rate does not increase, to function as required at the end approach in order to deliver better original design requirements of the asset. This will be existing assets that are failing to sewer pipeline products installed of this time the critical issue wholelife value.

622 | |00British British Month Precast Precast 2012 www.cnplus.co.uk www.cnplus.co.uk British00 Month Precast 2012 | 7| 7 Sustainability: Working service life The whole picture Measuring costs on the basis of total expenditure – known as totex – can help to deliver better whole-life value cross the built Specified Design Life Vs Working Service Life of Different Products environment there are many examples where it Ais short-sighted to solely consider capital expenditure without any consideration of DL Specified (SL) Product A (SL) SERVICE LIFE (SL) Product B operational costs and lifespan. DESIGN LIFE Precast products, including SERVICE LIFE concrete masonry, have exceptional durability and this (DL) can offer distinct advantages to clients in sectors such as housing, education, transport, energy and water. It is from the last of these sectors that the issue is explored in detail below.

622 | |00British British Month Precast Precast 2012 www.cnplus.co.uk www.cnplus.co.uk British00 Month Precast 2012 | 7| 7 Sustainability: Environmental Product Declarations Connection systems for concrete frame construction. Simple and invisible… Higher standards British Precast’s Environmental Product Declarations will support project teams to develop sustainable solutions

he first quarter of 2017 will all but the largest manufacturers. see British Precast publish To make the tool stand out from a set of generic industry- others emerging on the market Taverage Environmental British Precast has tailored the tool Product Declarations (EPDs) for use by precast concrete, mortar relating to a wide range of precast and ready-mix manufacturers. The and concrete masonry products. tool has an extensive list of more The EPDs will be published than 50 material inputs covering through the IBU Verification all the commonly used aggregates, Scheme. This is currently Europe’s cements, reinforcements and Our products make the most recognised and established admixtures. Importantly, scheme for the publication of carbonation calculations are also following concrete EPDs in accordance with EN 15804. built into the LCA tool, giving a connections... Sections of the construction fuller understanding of a products industry are still largely unaware carbon footprint past the factory ■ of EPDs but the application of gate. Providing this information precast-to-precast product lifecycle analysis is likely should enable the construction ■ precast-to-insitu to be an important growth area. industry to make informed choices ■ The benefits are not only in the about the whole-life impact of insitu-to-insitu future: even now, having EPDs can precast concrete products. The tool provide assistance for projects is compatible with the upcoming Simple and invisible... seeking high BREEAM ratings. concrete EPD standard prEN 16757 They are one of the tools that will and can be used by companies to help us put data behind our support compliance to the new understanding of the whole-life Carbon Management standard PAS impact of the built environment 2080. and play a key role in the ability of The range of generic product construction product suppliers to EPDs will include aggregate and …see them at invisibleconnections.co.uk maximise the benefits that BIM aircrete blocks, cladding, beams, offers. paving and box culverts. There are Having an EPD for a product two purposes for these generic doesn’t signify good product EPDs. Firstly, at the environmental performance – it is earliest design stages the supplier simply verified information that is unknown, so an industry-wide can be used in resource planning EPD will be helpful. Secondly, and benchmarking. For this generic EPDs will act as a bridge reason, producing EPDs is for members of British Precast to beneficial for all types of product represent their products to and not just special eco-design customers before a move to more ranges. British Precast’s Nick Gorst (right) receiving the official certification for companies publishing their own The EPD sets out data for a Environmental Product Declaration for British Precast from Burkhart EPDs. range of key environmental Lehmann, chairman of IBU Starting from January 2017, indicators including global British Precast will start offering Invisible Connections Ltd warming potential (carbon), Thinkstep on developing a an Environmental Product ozone depletion, acidification lifecycle assessment tool for the Declaration (EPD) development Unit 6 | Thame Forty | Jane Morbey Road | Thame | Oxfordshire | OX9 3RR potential, a range of material and Producing EPDs is purpose of producing verified and verification service for precast Telephone +44 (0)1844 266000 | Fax +44 (0)1844 390167 energy depletion metrics. It is beneficial for all Environmental Product concrete products manufactured valid for a five-year period. Declarations (EPDs) in accordance by full members of the federation. [email protected] | www.invisibleconnections.co.uk types of product with BS EN 15804: 2012 +A1 (2013). Lifecycle assessment and not just special The tool created had to be robust For more information on the British Over the past two years, British and accurate but also usable in a Precast EPD project and tool, contact eco-design ranges TECHNICAL Precast has worked closely with market where the production of [email protected] or call APPROVAL 1398 5056 sustainability consultant EPDs can be cost prohibitive for 0116 232 5170

8 | 00British Month Precast 2012 www.cnplus.co.uk Sustainability: Environmental Product Declarations Connection systems for concrete frame construction. Simple and invisible… Higher standards British Precast’s Environmental Product Declarations will support project teams to develop sustainable solutions

8 | 00British Month Precast 2012 www.cnplus.co.uk Building Information Modelling Precast Concrete Solutions Explaining LEXiCON Providing designers, contractors and clients with consistent product data

hile digitalisation of For the leading edge companies while each manufacturer holds its the construction in construction, this is sorely own data but can be confident industry is under MPA-British needed, even though they have that there is a level playing field Wway, there is still Precast has been developed workarounds and their across the digital environment. much to do to develop and own systems. Equally, the SME Work is going ahead in all of coordinate product information. there right at the top community suffers from being the necessary areas but there is no Drainage Retaining Walls Specialist Precast This information is needed so of the list from the unable to join in. denying this has taken longer that clients, specifiers, designers beginning, and is LEXiCON will allow common than first imagined. and a multitude of end-users can terms and common arrangement However, no one has attempted have access to consistent and going to be of data across the product sector. this on any level before and to comparable information across one of the first Unlocking comparison of ensure it caters for everyone, there the whole product arena to information for clients designers is still a lot to be done. Equally, we enable BIM to be as effective as organisations to be and ensuring that construction are still looking for more partners possible. put through the and FM teams have reliable to ensure as wider community as The approach to product data information. possible. has been, at best, chaotic until Relevant Authority A key feature is the During the development of the now. Many leading manufacturers registration process establishment of Relevant programme, we have seen the have progressed their offerings Authorities – these are trade establishment of the UK BIM and developed sophisticated bodies or groups who can use alliance. From the start, mutual digital portfolios with 3D the software to establish terms recognition and support has been graphic and data sets. However, and data formats that fit their there. there has been little in the way of trade that are common and Once LEXiCON has been fully coordination across the sector. machine readable. They are launched for products, its use Several trade bodies have taken the best-placed to agree this, under the authority of the alliance the initiative and developed then allow individual for processes can begin. This Water Management Rail Off-Site Solutions this one stage further with manufactures to use these opens up an even more exciting programmes to join up in their data. prospect for all data right across information across their sector. Existing systems can work the industry. A pan-sector, all encompassing, within the LEXiCON The development team at The CPM Group is a market leading manufacturer of concrete products, with production facilities across the UK. reliable and consistent approach arrangement, ensuring that CPA with full support by This, combined with a network of specialist distributors, enables us to provide our customers with complete coverage. has been lacking. Even the well- previous effort is not lost. BIM4M2 members have been established global organisations delighted at the response from The CPM business is built on a solid reputation for delivering high quality products and providing a ﬁ rst class service, with have found it difficult to bring Brexit considerations industry. In particular, MPA- diversiﬁ cation and innovation a key to our strength, we supply a vast range of sustainable precast products to every sector together the necessary level of Interest is also being found in British Precast has been there of the construction industry, fully supported by our experienced technical and engineering teams who are here to help you. consistency. Europe. While we do not know the right atthe top of the list effect of Brexit, ensuring the from the beginning, and is To download our BIM product information and our free Redi-Rock™ An end to frustration system can work with and around going to be one of the first design software please visit www.cpm-group.com The LEXiCON project attempts to European standards data and organisations to be put through put an end to this situation. products is critical. the Relevant Authority It was conceived out of the Standards working groups in registration process. frustration in the construction CEN and other programmes such Very shortly, we will be product sector to ensure digital as Smart CE Marking are inviting small groups to take consistency and that full coordinating their efforts with the part in the early testing and T: 01179 814500 advantage is made both for programme. Relevant Authority training – F: 01179 814511 manufacturers and clients. Interest in the project has been this will enable a slowly ramping E: [email protected] The ability for joined-up very positive, with many up learning and refining as www.cpm-group.com information to develop the organisations wanting to register we go. A small step for market and greatly increase as Relevant Authorities from the manufacturers, but a huge leap efficiency and productivity is very first announcement. for product data. obvious. Each relevant authority can Ensuring that everyone has have autonomy of its community Peter Caplehorn is Construction access and can benefit is more and ensure that the organisation Products Association deputy chief complex. of the data suits its members, executive and policy director Concrete for Life

10 | 00British Month Precast 2012 www.cnplus.co.uk Building Information Modelling Precast Concrete Solutions Explaining LEXiCON Providing designers, contractors and clients with consistent product data

10 | 00British Month Precast 2012 www.cnplus.co.uk Sustainable Urban Drainage Systems A chance of heavy rain Sustainable urban drainage systems control water runoff close to where it falls, mimicking natural drainage as closely as possible – reducing the causes and impact of flooding in the process

here are precast sustainable urban drainage systems (SuDS) SuDS can remove Tcomponents and pollutants at source guidance available for designers and installers to play their part in and combine water reducing surface flooding. management with Causes of flooding green space In environments that have been modified by human activity, ground surfaces tend to be less or slow down runoff before it can permeable than those in a natural inundate outfalls. landscape. Consequently, more In addition to reducing the rainfall turns into surface water causes and impact of flooding, runoff. In built-up areas, this SuDS can also remove pollutants runoff is usually collected and at source and combine water conveyed away by public drains management with green space, ATT enuATion And sTorAge and sewers or by open or culverted benefiting wildlife and watercourses. recreational users. The CIRIA SuDS Manual, published in November 2015, provides guidance The flow is then transported to on the design, construction, operation and maintenance of attenuation an outfall some distance away, Hard and soft and storage tanks. Further information can be found in the CPSA publication typically into a surface water body. Designers have the option of using Storm Water Attenuation Storage Tanks for Sustainable Drainage (SuDS) The time taken for the flow to reach hard and soft SuDS solutions. Soft Applications. the outfall is considerably less than SuDS are generally landscaped, the natural pathway of rain falling vegetated features such as swales For more information, visit www.concretepipes.co.uk on undeveloped land and the and detention ponds. Hard SuDS combined effect of the shorter include concrete block permeable transport time plus increased paving and proprietary- runoff from impermeable surfaces engineered products installed Pervious PAving landscape, including: means that flooding and pollution underground, such as precast Pervious surfacing comprises • It is a prefabricated recyclable events are more likely. concrete soakaways, attenuation hard-paved areas that carry traffic product Climate change models predict tanks and treatment chambers. and/or pedestrians and allow water • It can be installed mechanically, that heavy rainfall events with Soft SuDS can provide amenity to pass through. Concrete block allowing large areas to be laid with a associated flooding will become to a development. The downside is permeable paving is a popular form minimum of manpower, saving time more prevalent. that vegetated features often of pervious surfacing, in which the and money require larger areas of land that joints or voids between the concrete • It can be used immediately after Solutions could otherwise have been used blocks are filled with a free-draining the laying procedures have been In the UK, providing increased for development. material. completed capacity within the sewer By contrast, proprietary solutions The joints allow rainwater to pass • It has excellent load-bearing network to deal with increased – such as precast concrete between the concrete blocks and capabilities volumes of surface water is underground storage, flow control into the underlying permeable • It can tolerate settlement and PERI PRECAST SOLUTIONS – generally unaffordable. and attenuation systems – can be sub-base where it is stored (storage) differential movement Time-saving solutions for the precast industry. Another possible solution lies sited under access roads, for and then released slowly into the • It is unaffected by frost or de-icing ground (infiltration), or to the next salts in modifying the urban landscape. example, to help ameliorate runoff Formwork PROKIT temporary edge protection is part of a wide range of PERI products SuDS management stage or to a • It requires only minimal This can be achieved through the without using valuable land. Scaffolding and accessories to improve safety, save time and increase labour efficiency use of SuDS, which are designed to The most appropriate and cost- drainage system (conveyance). maintenance over its long life. Engineering on site. The PERI range includes flexible PERI UP stair towers, push-pull control runoff close to where it effective sustainable drainage There are numerous advantages props, high-load capacity MULTIPROP and PERI PAVE production pallets. to using concrete block permeable For more information, visit www.peri.ltd.uk falls and mimic natural drainage solution will often involve a paving as part of an urban www.paving.org.uk as closely as possible. Put simply, balance of both hard and soft For more information, please visit www.peri.ltd.uk. the landscape is used to store and/ SuDS components.

1222 | | 00BritishBritish Month Precast Precast 2012 www.cnplus.co.uk Sustainable Urban Drainage Systems A chance of heavy rain Sustainable urban drainage systems control water runoff close to where it falls, mimicking natural drainage as closely as possible – reducing the causes and impact of flooding in the process

1222 | | 00BritishBritish Month Precast Precast 2012 www.cnplus.co.uk Sustainability: Optimising design Offsite In the pipeline Overcoming risks The use of rigid pipes gives pipeline installers the option of using alternatives to Class S bedding Adopting offsite exposes designers and clients to risk. Precast concrete overcomes these concerns for a buried pipeline installation. This change could result in significant cost savings

recast concrete can be To address this, the chief fire used for all building types officers are trying to register all ome drainage The prominence of sustainability and infrastructure new timber framed buildings but installations are still fully in the decision making of designers Pprojects. It overcomes the scheme is voluntary. Some local surrounding pipelines in and contractors is growing risks associated with other offsite authorities are trying to introduce Sexpensive imported construction methods, and it is a information plates for buildings granular bedding, yet a more local product with strong that are timber framed. These considered approach to the design In reality, this means that most sustainability and performance initiatives highlight the problem and selection of the pipe material standard plastic sewer pipes are credentials backed up by many and look to mitigate risks, but they could result in the use of a less installed with Class S bedding. years of experience. Typical risks do not reduce the potential wider costly, lower-carbon installation. This requires a pipe to be of offsite construction are liabilities arising from CDM Bedding, or embedment, is used completely surrounded with addressed below, and an obligations. Non-combustible to transfer loads between a buried granular material to effectively explanation is given of how solutions reduce these risks. pipe and the surrounding earth. distribute any loads. precast concrete mitigates them. Overheating resilience The Zero There are various classes of Product standards Precast Carbon Hub may have been bedding. The main differences Concrete strength concrete has long-established wound up in 2016, but its between classes relate to the type By contrast, the inherent strength standards for products through warnings to government of the of material used and the areas of concrete pipes means the use of BSI and many of these are risks of overheating should be around the circumference of the Class S bedding is often an harmonised across Europe Fully factory-finished sandwich panels for building envelopes heeded. Responsible developers pipe where the bedding material expensive over-specification through CEN. Therefore, many and informed building owners are is placed. when cheaper, less carbon- precast products are CE-marked A robust supply chain The Durability/robustness during increasingly aware of the major The contribution of bedding to intensive options such as Class B as normal practice. This enables membership of British Precast is construction Is there a better risk of current and future the performance of a pipe is bedding can be utilised. Class B designers and project teams to extensive, with many members material for delivery to a building overheating. With the right particularly important in the case requires a pipe to be surrounded quantity of granular bedding specify their offsite products with producing a wide range of site than concrete when it comes design and good ventilation, the of flexible pipes because they have by considerably less granular material necessitated by the use of greater confidence. This also products. This provides project to being durable and robust? It inherent thermal mass of precast relatively little inherent strength material but still provides an Class S for flexible pipe It is clear that the equips contractors with the teams and contractors with a does not require the same concrete is ideally suited to absorb and derive a significant enhancement to the pipe’s load installations increases the whole-life carbon information to receive offsite competitive supply chain. This is protection from weather and heat to reduce peak temperatures. proportion of the structural carrying capabilities. embodied carbon in the installed products with the right quality beneficial at tender stage and impacts as lightweight solutions This overheating risk is strength from the embedment From an environmental pipeline and the amount of impact of concrete and performance parameters. reassuring so that the project is do. recognised in the Building placed at the sides of the pipeline. perspective, the additional excavated material that will be products is frequently Design codes The Eurocode not reliant on one possible Longevity during operation Regulations and the recent displaced by the bedding, which overestimated suite of design codes by CEN, with supplier. The precast concrete properties of housing white paper. Carbon impact and cost of different bedding classes may have to be trucked from site UK National Annexes by BSI, have Local supply Precast concrete is durability and robustness also Long lead-in Offsite solutions and disposed of in landfill. The now replaced the British codes, a local product. The majority of deliver a low-maintenance, long- have the disadvantage of requiring Case Study table shows how carbon emissions which have been withdrawn and precast used in the UK is made in lasting solution that reduces risks a longer lead in period. During this Volkswagen Car Showroom Service Centre, MSCP, London – PCE LTD Pipe diameter (DN) Flexible pipe Rigid pipe and costs of a drainage pipeline are no longer maintained. the UK from materials sourced in during operation. lead-in period, onsite in situ PCE delivered a multi-functional building for Volkswagen over 5 Class S Class B can vary depending on bedding Designers can use these Eurocodes the UK. This reduces the risk to Fire resistance during concrete works can be carried out; floors delivering areas for a showroom, service centre, offices and car (kgCO e /linear metre) (kgCO e/linear metre) construction 2 2 class for various pipe diameters. with offsite precast products exchange rate fluctuation, The HSE view is for example, foundations and the parking (7300m2) to a busy congested London site. They worked with (£/metre) (£/metre) because the precast product transport problems, clear – timber-frame solutions ground floor. In situ concrete and main contractor Longcross to win the project with an alternative Carbon impact standards and design codes have communication problems and pose higher risks. The timber precast concrete can be designed tender by proposing a precast solution. This solution utilised 300 8.72 4.41 The British Precast generic been developed simultaneously, difficulties in inspecting products industry has introduced and constructed together innovative GT slabs, box units for stair/lift cores, removed a central row £21.37 £12.76 Environmental Product with the purpose of being prior to leaving the factory. additional measures to be adopted seamlessly: same design codes, of columns, reduced lorry loads, reduced operatives on site, Declaration project will consistent with each other. by clients, designers and same material properties and incorporated architectural circular white columns and delivered the 600 20.64 10.40 determine not only the carbon A responsible supply chain manufacturers that seek to same jointing principles. project earlier. Furthermore, 3-D modelling during design and tight £49.22 £28.50 footprint but also a range of other overestimated and the true values British Precast members provide address these risks. However, the Non-repetitive elements With production control avoided clashes and erection delays. The project is a impacts across the whole life are actually significantly lower. responsibly sourced products. HSE advises that there is a duty of precast concrete offsite solutions, 1200 52.51 26.07 cycle of a concrete pipe. With The use of rigid pipes, such as With the BRE BES 6001 scheme, Precast overcomes care to reduce risk through design. the one-offs can be cost- £142.40 £85.92 preliminary results from the precast concrete, will often give the British Precast Charters for the risks associated This can most effectively be done effectively created with in situ ann

project, and with the recent pipeline installers the option of Sustainability and Health and by choosing concrete and concrete as it is wholly c publication of an article about using alternatives to Class S Safety – and all members with other offsite avoiding unnecessary fire load. compatible. For example, a foyer Assumes cost of imported granular bedding at £15/tonne and disposal cost of cement carbonation in Nature bedding for a buried pipeline operating under UK employment construction Fire resistance during in a hotel may not be suitable for excavated material taken to landfill at £6/tonne. Excludes cost of pipes and Geoscience, it is clear that the installation. This change in class laws – clients can fully address occupation Government statistics factory production but can be cast fittings. Bulk densities as per default values in CPSA Material Cost Calculator at whole-life carbon impact of could result in significant financial, risk by choosing from the British methods state timber frame solutions have a onsite while precast elements are age courtesy FP Mc

www.concretepipes.co.uk/calculators/material-cost concrete products is frequently environmental and time savings. Precast supply chain. higher risk of more extensive fires. installed elsewhere on the project. I M

1422 || 00BritishBritish Month PrecastPrecast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | 1515 Sustainability: Optimising design Offsite In the pipeline Overcoming risks The use of rigid pipes gives pipeline installers the option of using alternatives to Class S bedding Adopting offsite exposes designers and clients to risk. Precast concrete overcomes these concerns for a buried pipeline installation. This change could result in significant cost savings

1422 || 00BritishBritish Month PrecastPrecast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | 1515 British Precast Associate Members

Adfil Construction Fibres Dundee College Loughborough University Prothious Engineering Services Adomast Manufacturing Ltd Ecoratio Europe BV Lytag Ltd Pvt. Ltd Advantage Precast EKC Systems Ltd Mapei UK Ltd PUK Ltd THE TIMELESS CASE FOR CONCRETE BASF Construction Chemicals Elematic Oyj Martek Industries Ltd Resiblock Ltd BDS Marketing Research Ltd Elkem Materials Ltd Max Frank Ltd RFA-Tech Ltd The whole-life benefits that make concrete the perfect material for past, present and future Beresford’s Flooring Ltd Erico Europe BV (Pentair Group) Megasteel Ltd Rocan Products Ltd Besser Company Euro Accessories Limited Mentor Training Solutions Ltd Search Consultancy Bianchi Casseforme SRL Fosroc Limited Miers Construction Products ltd Shuttlelift BRE GCP Applied Technologies Ltd Moulded Foams Ltd SIKA Ltd C&CA Cement &Concrete Graceland Fixing Ltd N R Richards Associates Ltd Simply Precast Accessories Ltd Associates Ltd Halfen Limited National Precast Concrete Spiroll Precast Services Ltd Canadian Precast Institute Hanson Cement Limited Association Australia Strusoft UK Carbon8 Aggregates Ltd Havsco Ltd National Precast Concrete Tarmac Cement & Lime Limited Caswick Ltd Hendriks Precon B.V Association USA Tarmac Trading Limited Cathay Industries (UK) Ltd Hickman & Love (Tipton) Ltd Natural Cement Distribution Ltd The CPD Certification Service ENVIRONMENTAL SOCIAL ECONOMIC Cement and Concrete Association Hope Cement Ltd Net-Temps Ltd Trelleborg Pipe Seals of New Zealand Huntsman Pigments Parex Ltd Trimble Solutions (UK) Ltd Concrete is non-combustible, helping Concrete reduces the spread of fire, Regulations require the safe UK Certification authority for Cenin Limited Hydronix Ltd Patterns and Moulds Ltd to ensure its longevity and avoiding helping to provide life safety and evacuation of occupants but do Christeyns UK Ltd Identification Technologies PCE Limited Reinforcing Steels (Cares) the need for additional fire-proofing property safety. During construction, not ensure the survival of property. Chryso UK Ltd Scotland Ltd Peikko UK Ltd University College London materials. a concrete frame presents no fire risk Concrete structures comply with life Command Alkon UK Ltd Inter-Minerals PERI Ltd University of Brighton to neighbours. safety regulations but also resist fire to Concrete Manufacturers Invisible Connections Polarmatic Oy Juha Niemi University of Dundee FIRE RESISTANCE enable cost-effective repair and reuse. Association – South Africa N/A Isedio Ltd Precast Concrete Structures University of Nottingham Concrete Technology Ltd J & P Building Systems Limited Limited University of Sheffield Conspare Ltd Kingston University Precast Construction Technology University of Surrey Concrete’s thermal mass can reduce or The thermal mass inherent in concrete Using the thermal mass provided by avoid the need for mechanical cooling. provides long-term resilience to the concrete can lower the running costs Construction Fixing Systems Ltd KVM Industrimaskiner A/S Ltd University of Teesside This inherent property of concrete can issue of overheating – a growing health of a building. It can also reduce the Construx BUBA Lanxess Ltd Precast New Zealand Incorporated University of the West of England save hundreds of kilograms of CO over and wellbeing issue, particularly among amount of M&E equipment needed, Coote Engineering Ltd Larsen Building Products Precast/Prestressed Concrete University of the West of Scotland 2 a building’s life. the very young and the elderly. leading to lower operating and Cordek Limited Leading Edge Management Institute Waldeck Engineering Limited THERMAL MASS maintenance costs. CPI Worldwide Leca UK Pressvess Yara UK Ltd CSM Thermomass Leeds Oil + Grease Co. Ltd (LOGCO) Probst Handling Equipment Doncaster College Longrake Spar Co Ltd Progress Group The durability of concrete structures The durability of concrete structures Concrete is a very stable and durable helps them to achieve a long life and means that, once built, they are rarely material with an extremely long life. maximise their performance, keeping out of use for maintenance and hence As a result, maintenance costs are their whole-life environmental impact cause minimal social disruption. very low. to a minimum. Resources from MPA The Concrete Centre DURABILITY Concrete offers good inherent acoustic Concrete’s mass provides a good Concrete provides good inherent performance, requiring very little in barrier to noise, improving quality acoustic separation. This can result British Precast works with The Concrete Centre, which assists all those who the way of additional finishes and of life, particularly in high-density in cost savings because minimal materials, which often have a short housing or near busy roads. supplementary design measures design and construct in concrete to fully realise the potential of the material lifespan. As a result, less material is are required. ACOUSTIC ISOLATION used and potential waste is avoided PERFORMANCE over the life of the building. Events Brochures include: • Performance issues, including performance, airtightness, flood The Concrete Centre offers a range • Methods of construction, Fire, Flooding, Thermal resilience and designing to of events, from free, online including Crosswall Construction, Performance and Thermal Mass; Eurocode 6. Concrete can provide a robust, Solid concrete and masonry party Concrete structures, particularly those webinars to conferences and short Hybrid Concrete Construction, • Sustainability including • Technical Guidance Books finished surface, avoiding the need walls result in safe, secure buildings, with minimal finishes, will suffer courses, covering a range of best Precast Concrete in Buildings and Concrete and BREEAM, Concrete include Concise Eurocode 2, for additional materials, which would preventing unwelcome intruders. less damage and cost less to repair practice topics on concrete. These Precast Concrete in Civil Credentials and Whole Life Residential Cellular Concrete require maintenance and periodic and maintain. events are CPD-certified and Engineering; Carbon; Buildings, Design of Hybrid replacement over a building’s lifecycle. delivered by technical experts • Market sectors, including ‘How To’ Technical Guidance Concrete Buildings and ROBUSTNESS and/or representatives from Housing, Schools, Offices, Brochures include: Concrete Buildings Scheme AND SECURITY project teams presenting their Hospitals, Car Parks and Bridges; • Masonry documents on acoustic Design Manual. Concrete retains its structural integrity, Concrete and masonry structures Downtime of businesses, homes view of concrete exemplars. For resulting in minimal waste of materials can be designed to resist water and essential community services is more information on forthcoming following a flood. penetration, keeping inconvenience minimised if flooded buildings have events, visit the events calendar at and disruption to businesses, been constructed in concrete, as www.concretecentre.com/events. homeowners and the community to they will require less repair work. a minimum. Publications FLOOD RESILIENCE The Concrete Centre produces a range of publications. To access the full list , visit www. concretecentre.com/publications. For more information visit www.concretecentre.com

16 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 1717 British Precast Associate Members

16 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 1717 British Precast Buyers Guide Visit www.britishprecast.org/buyersguide for interactive online version

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 1. ABM Precast Solutions Agricultural Products 2. Acheson & Glover Arch, Portal & Box Structures 3. ACP (Concrete) 4. Aggregate Industries Architectural Dressings 5. Amber Precast Basement Units 6. Banagher Precast Concrete Beam & Block Floors 7. Barcon Systems Beams & Columns 8. Besblock 9. Bison Manufacturing Bespoke Products 10. Blanc de Bierges Block Paving 11. Breedon Aggregates Blocks, Inner Leaf & Partition 12. Brett Landscaping Blocks, Outer Leaf 13. Broome Bros (Doncaster) 14. Castle Construction Products Box Culverts 15. CEMEX UK Bridge Beams & Gantries 16. Charcon Construction Solutions Cast Stone Architectural Units 17. CCP Building Products 18. Collier Quarrying & Recycling Cladding & Structural Wall Units 19. Cornish Concrete Products Composite & Double Tee Floors 20. CPM Group Concrete Bricks 21. Creagh Concrete Products Decorative Internal Surfaces 22. Cross Concrete Flooring 23. Decomo UK Decorative Paving 24. Delta Bloc UK Dock Leveller Pits 25. E&JW Glendinning Ducts, Conduits & Markers 26. Ebor Concretes Fencing 27. Elite Precast 28. Evans Concrete Products Flags 29. F P McCann Flat Pack Systems 30. Forterra Building Products Foundation Blocks 31. Forticrete 32. H+H UK Foundation Units & Piles 33. Hillhouse Quarry Group Frames 34. Interfuse Garden Products 35. Jordan Concrete Grandstands & Terracing 36. Laird Bros 37. Lignacite Ground Beams 38. Litecast Hollowcore Floors 39. Longley Concrete Kerbs 40. Marshalls Lighting Columns & Transmission Poles 41. Milton Precast 42. Mona Precast Lintels Sills & Copings 43. Naylor Concrete Products Manholes & Inspection Chambers 44. Newlay Concrete Multi-storey Carparks 45. Patersons Quarries Packed Products 46. Plasmor 47. Premium Concrete Products Pipes 48. Quinn Building Products Pods 49. Robeslee Concrete Prefabricated Buildings 50. S. Morris 51. Sellite Blocks Railway Sleepers, Bearers & Units 52. Skene Concrete Products Reinforced Aircrete Floors 53. Specialist Precast Products Retaining, Revetment & Crib Walls 54. Stanton Bonna Concrete Road Surface Drainage 55. Sterling Services 56. Stocks Blocks Roof Tiles 57. Stowell Concrete Sea & River Defence Units 58. Supreme Concrete Specialised Building Systems 59. Tarmac Building Products Staircases & Stair Units 60. Techrete 61. Thakeham Tiles Street Furniture & Bollards 62. Thomas Armstrong Tunnel Linings 63. Thorp Precast Vehicle Safety Barriers 64. Townscape Products 65. TT Concrete Products Water Treatment & Storage Tanks 66. WDL Concrete Products 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

18 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | 231919 British Precast Buyers Guide Visit www.britishprecast.org/buyersguide for interactive online version

18 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | 231919 Offsite: Modular retaining walls Block booking Interlocking precast concrete blocks have been employed on a project to tame a water course

lite Precast has played an and materials to the site was An earth-retaining wall was remote location and poor access. similar geometrical proportions. integral role in always going to be difficult. The required to support the A modular solution using As a result, a Lego model of safeguarding the iconic first activity that the contractor, reconstructed slope and protect interlocking precast concrete the design was created and then E Settle and Carlisle Story Contracting, needed to do the embankment toe from blocks was identified. used on site to brief those railway line. The line, which was lay down a 1.4-mile haul road further scour. Additionally, a weir Elite Precast manufactures a working on the scheme as the is also a strategic through- from a twisting unclassified structure was needed to slow system known as Legato and full-scale Legato solution was route for Network Rail, runs public road to the site. Only then down the stream around the this was selected for the scheme. assembled. through the Yorkshire Dales could the slope stabilisation works embankment toe during periods The Legato blocks, each weighing Approximately 250 of the Legato National Park. begin. of high flow. up to 2.5 tonnes, are manufactured blocks were used to construct the The surrounding countryside At the top of the embankment using high strength concrete retaining wall and weir structure. is bleak, rugged, beautiful slope, a kingpost wall Interlocking blocks (50MPa), with a design life of Elite’s precast concrete blocks and wet – sometimes very wet. incorporating cess retention It quickly became clear to the 100 years. The blocks are also cast have now tamed the water course, A consequence of that high was constructed over a 62 m designer, AECOM, that the earth- with lifting eyes, making reducing the speed of Cowgill annual rainfall is that the length. However, the main retaining wall and weir structure reassembly on site relatively Beck when it is in spate and Settle and Carlisle line has construction activity focussed on would need to be manufactured simple. minimising the potential for suffered from drainage issues the toe of Dent Embankment and off site and then re assembled at While Legato is not related to scour of the adjacent slopes of since it was constructed in the Cowgill Beck. Dent Embankment due to the Lego, the two products possess Dent Embankment. 1870s. A short distance to the north of Dent station, which is the highest operational railway station in England, the railway line runs on embankment before entering Risehill tunnel. A watercourse, NEW known as Cowgill Beck, is culverted through the HTA-CE PLUS – With additional load capacity: embankment. Where the fast flowing stream emerges at the embankment toe, THE NEW HALFEN CHANNEL it has started to scour the All features at a glance: earthwork, thereby affecting the stability of the slope and causing  CE marking with European movement of the cess and track Technical Assessment at the top of the embankment. Remedial works were deemed necessary to first stabilise and  Suitable for dynamic loads then protect the slopes of Dent Embankment.  Hot rolled HALFEN Channels Transport challenge R 120 Due to the remote location and  2 hour fire rating poor road infrastructure, transporting plant, equipment  Up to 45% higher load capacity ing T  HALFEN product software rac T on The surrounding ontracting c c ory

countryside is rugged, tory sT beautiful and wet – esyof sometimes very wet T

T os cour www.halfen.co.uk PhoPhotos courtesy of s

2022 || British00 Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || XX2121 Offsite: Modular retaining walls Block booking Interlocking precast concrete blocks have been employed on a project to tame a water course lite Precast has played an and materials to the site was An earth-retaining wall was remote location and poor access. similar geometrical proportions. integral role in always going to be difficult. The required to support the A modular solution using As a result, a Lego model of safeguarding the iconic first activity that the contractor, reconstructed slope and protect interlocking precast concrete the design was created and then E Settle and Carlisle Story Contracting, needed to do the embankment toe from blocks was identified. used on site to brief those railway line. The line, which was lay down a 1.4-mile haul road further scour. Additionally, a weir Elite Precast manufactures a working on the scheme as the is also a strategic through- from a twisting unclassified structure was needed to slow system known as Legato and full-scale Legato solution was route for Network Rail, runs public road to the site. Only then down the stream around the this was selected for the scheme. assembled. through the Yorkshire Dales could the slope stabilisation works embankment toe during periods The Legato blocks, each weighing Approximately 250 of the Legato National Park. begin. of high flow. up to 2.5 tonnes, are manufactured blocks were used to construct the The surrounding countryside At the top of the embankment using high strength concrete retaining wall and weir structure. is bleak, rugged, beautiful slope, a kingpost wall Interlocking blocks (50MPa), with a design life of Elite’s precast concrete blocks and wet – sometimes very wet. incorporating cess retention It quickly became clear to the 100 years. The blocks are also cast have now tamed the water course, A consequence of that high was constructed over a 62 m designer, AECOM, that the earth- with lifting eyes, making reducing the speed of Cowgill annual rainfall is that the length. However, the main retaining wall and weir structure reassembly on site relatively Beck when it is in spate and Settle and Carlisle line has construction activity focussed on would need to be manufactured simple. minimising the potential for suffered from drainage issues the toe of Dent Embankment and off site and then re assembled at While Legato is not related to scour of the adjacent slopes of since it was constructed in the Cowgill Beck. Dent Embankment due to the Lego, the two products possess Dent Embankment. 1870s. A short distance to the north of Dent station, which is the highest operational railway station in England, the railway line runs on embankment before entering Risehill tunnel. A watercourse, NEW known as Cowgill Beck, is culverted through the HTA-CE PLUS – With additional load capacity: embankment. Where the fast flowing stream emerges at the embankment toe, THE NEW HALFEN CHANNEL it has started to scour the All features at a glance: earthwork, thereby affecting the stability of the slope and causing  CE marking with European movement of the cess and track Technical Assessment at the top of the embankment. Remedial works were deemed necessary to first stabilise and  Suitable for dynamic loads then protect the slopes of Dent Embankment.  Hot rolled HALFEN Channels Transport challenge R 120 Due to the remote location and  2 hour fire rating poor road infrastructure, transporting plant, equipment  Up to 45% higher load capacity ing T  HALFEN product software rac T on The surrounding ontracting c c ory countryside is rugged, tory sT beautiful and wet – esyof sometimes very wet T

T os cour www.halfen.co.uk PhotosPho courtesy of s

2022 || British00 Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || XX2121 Offsite: Case study

DRAINAGE FENCING FLOORING Adventures in precast Offsite manufactured bespoke flooring helped to deliver time and cost savings on a project in Derbyshire BUILDING o fast-track the build and facilitate follow-on trades, PRODUCTS RAIL a precast solution was Tchosen for the Mount Cook Adventure Centre in Derbyshire. The new centre, which is set in five acres of grounds, comprises a THINK YOU KNOW complex hexagonal central core design with two rectangular wings. It can accommodate 130 guests, who take part in a range of AGRICULTURAL FPMCCANN.CO.UK adventure activities such as rock FP McCANN? climbing, kayaking and orienteering. The eco-building at the centre uses solar power to generate hot water and electricity, rainwater collection to flush toilets and air-source heat to warm the rooms. Bespoke block and beam TUNNELS flooring, comprising pre-stressed SPECIALIST concrete beams with standard PRECAST concrete infill blocks laid in & SHAFTS between, was chosen for the complicated central core area on the ground floor. Hollowcore flooring slabs, which range from 150 mm to 400 mm and achieve a rapid strength of over 60N at only 28 days, were used to POWER & floor the building’s rectangular wings. INFRA- ARCHITECTURAL A heavy-density Hollowcore STRUCTURE & STRUCTURAL WALLING sound slab was used on the first floor and roof level to effectively meet acoustic requirements. Two beam and Hollowcore flooring In addition to supplying quality precast staircases, manufactured systems meant there was no need “We needed to offsite manufactured precast using custom-built moulds, were to wait for concrete slabs to cure. products, Charcon Construction also supplied and installed. Once grouted, floors formed a value-engineer Solutions offered a fully integrated ready-to-work base for follow-on a solution that solution on the project, providing Complex construction trades. Novus direct access to its design Charcon Construction Solutions “Additionally, Hollowcore is very would fast-track and planning expertise. TANKS & DOCK general manager Richard Baldry, easy to transport and handle construction and Novus Solutions commercial who supplied and installed the during construction, and requires allow immediate manager Dean Povey says: CHAMBERS LEVELLERS precast, says: “Due to the less material to manufacture “Charcon Construction Solutions complexity of the building’s compared to solid concrete slabs. access to follow-on carried out a difficult project in a design, we needed to value- This reduces carbon emissions. trades” difficult location under extreme AGRICULTURAL 01594 847500 ARCHITECTURAL & STRUCTURAL 020 3905 7640 / engineer a solution that would Providing stairs, manufactured weather conditions and on budget 01476 562277 / 01606 843500 BUILDING PRODUCTS 028 6772 1286 / 01335 361269 fast-track construction and allow offsite, also ensured a cost- and – a job well done.” DOCK LEVELLERS 01335 361269 DRAINAGE 01530 240000 / 028 7954 9026 immediate access to follow-on time-effective alternative to FENCING 01455 290780 FLOORING 01335 361269 RAIL | POWER & INFRASTRUCTURE trades. traditional timber-built For further information, visit “Using our precast block and staircases.” www. aspa-uk.org 01455 290780 SPECIALIST PRECAST 01353 861416 TANKS & CHAMBERS 01789 336960 TUNNELS & SHAFTS 01455 290780 WALLING 01594 847500 22 | 00British Month Precast 2012 www.cnplus.co.uk Offsite: Case study

ornish Concrete Products landings at each storey. has designed, supplied Sections were All precast components were Drainage Bridge Beams Tunnel Segments Pressure Pipe and installed two feature modelled in landed on props, lined and Cstaircases for a new levelled. All units were stitched 9,350 sq m four-storey office Solidworks and together in situ and only when building at BP’s International AutoCad as the in situ stitching and adjacent Centre for Business and frame concrete slabs had achieved Technology at Sunbury-on- independent checks the necessary strength could the Thames. on compatibility propping be sequentially Working from an outline dismantled. design of the staircase by Buro All units were cast in a high- Happold, Cornish Concrete liaison required during the strength mix with white Portland Products’ engineers carried out detailed design called for some cement, as well as white dolomite the detailed design of the re-analysis of the stairs to coarse and fine aggregates. Units individual precast elements and check suggested changes to the were then fair-faced and finally 0115 944 1448 DOWNLOAD connections. During this process, moulds to ease fabrication and acid-etched to bring out the [email protected] BROCHURE the proposed in situ concrete improve the final visual attractive sparkle from the mica www.stanton-bonna.co.uk solution was switched to precast All precast elements cantilever appearance. content of the aggregate. The to achieve the required finish and from a curved central spine beam To ensure all precast elements staircase was completed by quality. All precast elements would fit together on site, the adding a contrasting inset natural cantilever from a curved central curved and tapered sections were stone tread and riser overlaid to spine beam, which is partly recesses and cast-in conduits for modelled in 3D using both conceal the complexity of the EUREURO 1992 - 2017 reinforced with 25 mm solid steel lighting and balustrading, Solidworks and AutoCad as construction underneath. ACCCESSORIESCESSORIES plate. co-ordinated with the independent checks on For further case studies from the reinforcement and embedded compatibility. The only th Further analysis Architectural and Structural Precast 2 steel sections to provide the connections to the in-situ concrete Anniversary5 All precast units included rebates, necessary cover. The extensive frame were the cantilevered full Association, visit www.aspa-uk.org Threaded Rebar are cast into the walls for electrics and communications networks. Connection Couplers Walls and ceilings are to a A university challenge quality fair-face finish, allowing for a simple gypsum wash before Benefits Modular precast construction delivers high performance at a campus project final decoration. As part of the Full CARES Technical Approval in accordance with BS8110-Part 1. project, 541 individual bathroom Simplifies shutter design. pods are also being installed. t Modwen, the construction required a total of Reduces damage to formwork. regeneration specialist 2,400 precast wall, floor, stair and Precast benefits No specialist tools required. TERWA behind the new £450m landing elements. The precast modular building Provides a full bar strength coupling. Quality Assurance SSwansea University Bay Gable walls and party walls are system offers excellent acoustic Connection made utilising standard metric threads. Campus, has delivered an 160 mm thick, with each room and thermal mass properties as Full tension lap bar lengths available from stock. additional £50m of student floor slab 175 mm thick. All well as fire-resistant qualities accommodation and student horizontal and vertical elements associated with precast concrete. Reduces the risks associated with projecting reinforcement.

S Reduces the overall dimensions of precast units. facilities at the site. are designed for ease of build, Precast crosswall also offers TECHNICAL 50 t EC Declaration of Conformity C APPROVAL te

e fur McCann (Bell and Webster) high-strength non-shrink grout, hard by its short-term occupants. Bautechnik KOMO y ACM

successfully tendered for the fully conforming with Building The crosswall construction at S supply-and-install contract on Regulations. Wall panels, of course, Swansea University required For further case studies from the 0845 052 4050 ourte C 2,400 precast wall, floor, stair Architectural and Structural Precast C E R T I F I E D E N V I R O N M E N TA L

student accommodation are cast with window and door ge e. [email protected] w. www.euroacc.co.uk M A N A G E M E N T S Y S T E M

buildings 15 and 16. The crosswall openings, but in addition conduits and landing elements Association, visit www.aspa-uk.org I MA

24 | 00British Month Precast 2012 www.cnplus.co.uk Case studies Precast steps forward A proposed in situ concrete solution is switched to precast to achieve the required finish and quality INNOVATIVE PRECAST ornish Concrete Products landings at each storey. has designed, supplied Sections were All precast components were Drainage Bridge Beams Tunnel Segments Pressure Pipe and installed two feature modelled in landed on props, lined and Cstaircases for a new levelled. All units were stitched 9,350 sq m four-storey office Solidworks and together in situ and only when building at BP’s International AutoCad as the in situ stitching and adjacent Centre for Business and frame concrete slabs had achieved Technology at Sunbury-on- independent checks the necessary strength could the Thames. on compatibility propping be sequentially Working from an outline dismantled. design of the staircase by Buro All units were cast in a high- Happold, Cornish Concrete liaison required during the strength mix with white Portland Products’ engineers carried out detailed design called for some cement, as well as white dolomite the detailed design of the re-analysis of the stairs to coarse and fine aggregates. Units individual precast elements and check suggested changes to the were then fair-faced and finally 0115 944 1448 DOWNLOAD connections. During this process, moulds to ease fabrication and acid-etched to bring out the [email protected] BROCHURE the proposed in situ concrete improve the final visual attractive sparkle from the mica www.stanton-bonna.co.uk solution was switched to precast All precast elements cantilever appearance. content of the aggregate. The to achieve the required finish and from a curved central spine beam To ensure all precast elements staircase was completed by quality. All precast elements would fit together on site, the adding a contrasting inset natural cantilever from a curved central curved and tapered sections were stone tread and riser overlaid to spine beam, which is partly recesses and cast-in conduits for modelled in 3D using both conceal the complexity of the EUREURO 1992 - 2017 reinforced with 25 mm solid steel lighting and balustrading, Solidworks and AutoCad as construction underneath. ACCCESSORIESCESSORIES plate. co-ordinated with the independent checks on For further case studies from the reinforcement and embedded compatibility. The only th Further analysis Architectural and Structural Precast 2 steel sections to provide the connections to the in-situ concrete Anniversary5 All precast units included rebates, necessary cover. The extensive frame were the cantilevered full Association, visit www.aspa-uk.org Threaded Rebar are cast into the walls for electrics and communications networks. Connection Couplers Walls and ceilings are to a A university challenge quality fair-face finish, allowing for a simple gypsum wash before Benefits Modular precast construction delivers high performance at a campus project final decoration. As part of the Full CARES Technical Approval in accordance with BS8110-Part 1. project, 541 individual bathroom Simplifies shutter design. pods are also being installed. t Modwen, the construction required a total of Reduces damage to formwork. regeneration specialist 2,400 precast wall, floor, stair and Precast benefits No specialist tools required. TERWA behind the new £450m landing elements. The precast modular building Provides a full bar strength coupling. Quality Assurance SSwansea University Bay Gable walls and party walls are system offers excellent acoustic Connection made utilising standard metric threads. Campus, has delivered an 160 mm thick, with each room and thermal mass properties as Full tension lap bar lengths available from stock. additional £50m of student floor slab 175 mm thick. All well as fire-resistant qualities accommodation and student horizontal and vertical elements associated with precast concrete. Reduces the risks associated with projecting reinforcement.

S Reduces the overall dimensions of precast units. facilities at the site. are designed for ease of build, Precast crosswall also offers TECHNICAL 50 t EC Declaration of Conformity C APPROVAL te

Precast modular building linking together with hidden tie inherent robustness for I Improved transport costs. h C Deutsches installation contractor FP rods. Joints are finished with a accommodation that is worked Institut Ar Easier handling and installation. e fur McCann (Bell and Webster) high-strength non-shrink grout, hard by its short-term occupants. Bautechnik KOMO y ACM successfully tendered for the fully conforming with Building The crosswall construction at S supply-and-install contract on Regulations. Wall panels, of course, Swansea University required For further case studies from the 0845 052 4050 ourte C 2,400 precast wall, floor, stair Architectural and Structural Precast C E R T I F I E D E N V I R O N M E N TA L student accommodation are cast with window and door ge e. [email protected] w. www.euroacc.co.uk M A N A G E M E N T S Y S T E M buildings 15 and 16. The crosswall openings, but in addition conduits and landing elements Association, visit www.aspa-uk.org I MA

24 | 00British Month Precast 2012 www.cnplus.co.uk Manhole systems Installation: Pipe lifting An offsite solution Construction gets a lift A factory-manufactured precast manhole system uses less concrete than the onsite The Concrete Pipeline Systems Association has been instrumental in the introduction of a concrete pipe lifter equivalent, delivering savings of embodied carbon of up to 43 per cent per manhole

he risk of injury from manual handling is a key ompared to traditional in reduction if all traditional in situ issue for construction site situ construction constructed manhole systems Tworkers and the moving methods, offsite converted to the new precast base of large-diameter water pipes Cmanufactured circular system. There would also be less during delivery/offloading and concrete manhole systems are waste and excavated material to installation is a hazardous process. quicker and cheaper to install, be disposed of in landfill. The concrete pipe lifter addresses create less waste and, most these risks. important of all, they help Flexible system A factsheet produced by the improve safety on site. A circular precast manhole Concrete Pipeline Systems In fact, a circular precast comprises a concrete base unit, Association (CPSA) and available concrete manhole system has the complete with channels and from the CPSA website (www. potential to cut installation time benching and predetermined concretepipes.co.uk) is based on on site by up to 50 per cent and to combinations of inlet(s) and outlet. Health and Safety Executive best reduce installed costs by 15 to 30 The system is flexible enough to practice guidance, and per cent, particularly when enable special features, such as recommends that any pipe manholes are installed without a additional inlets, to be incorporated product of DN 300 or larger of any concrete surround. in the factory so that when the material should be mechanically Traditionally, contractors have system arrives on site it can quickly lifted. built manhole bases in situ in and safely be placed into position, To meet this site-handling issue, trenches to provide access for replacing the need for potentially CPSA has been instrumental in inspection and maintenance on hazardous site-based operations. the introduction of the concrete in-service wastewater drainage The system also includes a series pipe lifter into the UK market. and sewer systems. By contrast, of round chamber rings with This mechanical lifting device the offsite factory-manufactured watertight flexible joints, which attaches to standard excavator precast base solution also uses less are placed on the base unit to form equipment on site, using a quick- concrete than the onsite the access compartment. The hitch coupling. equivalent manhole, with a advantage of using a BS-compliant There are no hydraulic links or corresponding saving in embodied Kitemarked manhole solution is additional energy requirements carbon of up to 43 per cent per that users can be sure that the and the pipe lifter is suitable for manhole, which is equivalent to a product will comply with all standard UK specification BS EN

15,000 tonne CO2e annual necessary technical requirements. 1916 concrete pipes from DN 300 to DN 1200. A Type 2 Lifter is also The pipe lifter has no hydraulic links working operation, the concrete A circular precast concrete available for larger pipes from or additional energy requirements pipe lifter also provides a much CASE STUDY – ST hElEnS manhole system has the potential DN1350 to DN 2100. quicker method of working which, Users can be sure to cut installation time on site according to contractors who have Precast concrete manholes have been used to provide drainage access on that the product will by up to 50 per cent On the move used the product, will roughly the first government-supported self-build supersite development at French Once attached to the excavator, halve the time taken to offload and Fields, St Helens. The scheme is a partnership between developer Mark comply with all the pipe lifter can be used to to install pipes, thus increasing Ward, BuildStore and Kingspan Potton Homes, and comprises 18 individual necessary technical offload vehicles, move material to productivity and reducing site plots for detached custom-built homes. Each plot is ready for building to requirements an appropriate location for costs. commence and comes complete with access, services and site drainage storage and then manoeuvre the Introduced into the UK in 2012, already in place. pipes into the trench for the Concrete Pipe Lifter was The development makes extensive use of a precast concrete manhole installation. immediately recognised in the system to enable the quick and cost-effective construction of the foul Using the pipe lifter removes Water Industry Achievement drainage installation. The development includes six manholes, each with a the use of slings and chains, Awards, where it won the Health precast concrete monolithic multi-inlet base unit, complete with pre-formed and eliminates the need Using the pipe and Safety Category. It is a great channels and benching. The manhole’s robust design and watertight for anyone to work at height on lifter removes example of how relevant and thick-walled vertical chamber rings means that it can be installed without an the delivery vehicle, which was immediately applicable solutions in situ backfilled concrete surround, which enables the open excavation to the main objective in its the use of slings can be developed when various be backfilled sooner using excavated soil. development. and chains players in the industry work In addition to providing a safer together.

2622 || British00 Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 27 Manhole systems Installation: Pipe lifting An offsite solution Construction gets a lift A factory-manufactured precast manhole system uses less concrete than the onsite The Concrete Pipeline Systems Association has been instrumental in the introduction of a concrete pipe lifter equivalent, delivering savings of embodied carbon of up to 43 per cent per manhole

2622 || British00 Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 27 Installation: Modular paving Installation: Site safety Consistent quality Meeting CDM obligations Highway sector scheme 30 aims for quality of installation and reduced ongoing costs for client and supplier When it comes to precast flooring, using members of the Precast Flooring Federation and its Code of Practice for Safe Installation is a good start to ensuring you address health and safety on site

udget constraints was launched in 2013 at an event onstruction is a potentially heighten the importance in London attended by more than high-risk activity, as it of correct installation and 100 contractors, highways involves the use of heavy Brepair work for all paving engineers, local authority Cplant, cranes and personnel – and the highways sector scheme representatives and other working at height. Falls remain the NHSS30 raises the bar for modular interested professionals. A further biggest cause of deaths and serious paving. An industry awareness event to reinforce adoption of the injuries in construction. If work at event will be held this spring to scheme will be held this spring. height is properly planned, inform and guide both specifiers NHSS30 provides an industry including the correct selection of and contractors on how to benchmark, ensuring that project equipment and its appropriate use, effectively implement and use processes are planned and use then most accidents involving falls NHSS30. properly trained and competent can be prevented. This is one of the National Highway Sector installers. It focuses on goals of the Precast Flooring Schemes (NHSS) are management continuous improvement, quality Federation (PFF) and its Code of systems that address a range of of installation and reduced Practice for the Safe Installation of topics including surface ongoing costs for both the client Precast Concrete Flooring and treatments, road markings and and supplier. Competency is Associated Components. pothole repairs. They provide demonstrated by a combination of The third edition of the Code of confidence for the specifier and Modular paving includes paving • Promoting confidence in quality knowledge and assessed Practice was published in 2013. The client in the quality of installed blocks, flags, slabs, setts, kerbs and management systems by provision installation techniques, and PFF membership remains work. Scheme 30 in the NHSS accessories manufactured in precast of a robust, transparent system. covers both rigid and flexible committed to achieving a high suite covers the installation, concrete, natural stone or clay pavement constructions. standard and universal approach maintenance and repair of ISO 9001 framework Sector schemes are included in to health and safety. It is only by modular, small element paving. National Highway Sector Schemes the procurement process through the industry showing leadership Modular paving includes are bespoke integrated reference in the Specification for and taking ownership of the paving blocks, flags, slabs, setts, management schemes within an Highway Works (SHW) and all management of risk that kerbs and accessories ISO 9001 framework. They are sector scheme documents are improvements will be made. Part manufactured in precast concrete, written by technical advisory published directly by UKAS of this activity is the provision to properly used by designers in natural stone or clay. NHSS30 is a committees made up of (United Kingdom Accreditation employees, subcontractors, discharging their CDM scheme set up to improve the representatives from across the Service) – this is available for free designers and customers of clearly obligations, then the risks of death installed quality of all types of paving sector including clients, download from its website at presented information about and injury from falls and other modular paving products by: contractors, suppliers, www.ukas.com. current best practice for the factors should be greatly reduced. • Providing an industry manufacturers, trade associations, With a number of well-known installation of all types of precast The third edition is currently benchmark training organisations and contractors already registered flooring, such as beam-and-block available and the fourth edition • Ensuring that all processes are certification bodies. under NHSS30 and further and hollowcore. will soon be available as a free planned The NHSS30 scheme document companies already undergoing A fourth edition is soon to be download from the PFF website. • Providing a basis for continuous – the secretariat for which is assessment in preparation for published to take account of the Printed copies of the fourth improvement provided by British Precast registration, it is expected that the CDM Regulations 2015 and edition will made distributed to • Focusing on quality as an affiliate Interlay, the Association of scheme will enable the small- developments in best practice. It members, training organisations objective Paving Installers – gives details of element paving industry to is needed for the growing precast and the HSE. In parallel, a print • Reducing overall costs for the training requirements for improve significantly its flooring sector – we anticipate version of an abridged pocket- client and supplier operatives and supervisors, as well installation standards. Where the increasing use of precast flooring sized document, containing the • Providing and maintaining a as information on quality plans, quality of our road installations, as systems in the upper floors of key elements of the Code of properly trained and competent NHSS30 ensures an essential requirement of ISO well as repairs and maintenance, houses as demand for quiet and By working with PFF members you Practice, will be made available to workforce that project 9001. A dedicated scheme are under scrutiny, this will help durable floors grows. can help to ensure site safety construction site staff. • Involving all sides of the document to allow registered to control costs and improve The input of the Whether you are a client, a industry in scheme ownership processes are companies to adapt their systems confidence. Industry standard Health and Safety designer or a contractor, please within a partnership framework planned and use to include the requirements of ISO The input of the Health and Safety remember that by working with • Ensuring that certification 9000:2015 is due for release shortly. For further information on the NHSS30 Executive to this fourth edition, Executive establishes PFF members you can help to bodies are used whose auditors properly trained and NHSS30 aims to improve the scheme, how it operates and where through its detailed review, it as an industry ensure safety on your sites. have technical knowledge and competent installers installed quality of modular additional guidance and support can establishes it as an industry experience of the sector paving and is supported by be found, visit: www.interlay.org.uk/ standard. As with previous standard For more information, visit concerned Interlay as well as Interpave. It nhss30 editions, if the guidance is www.precastfloors.info

28 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | | 29 Installation: Modular paving Installation: Site safety Consistent quality Meeting CDM obligations Highway sector scheme 30 aims for quality of installation and reduced ongoing costs for client and supplier When it comes to precast flooring, using members of the Precast Flooring Federation and its Code of Practice for Safe Installation is a good start to ensuring you address health and safety on site udget constraints was launched in 2013 at an event onstruction is a potentially heighten the importance in London attended by more than high-risk activity, as it of correct installation and 100 contractors, highways involves the use of heavy Brepair work for all paving engineers, local authority Cplant, cranes and personnel – and the highways sector scheme representatives and other working at height. Falls remain the NHSS30 raises the bar for modular interested professionals. A further biggest cause of deaths and serious paving. An industry awareness event to reinforce adoption of the injuries in construction. If work at event will be held this spring to scheme will be held this spring. height is properly planned, inform and guide both specifiers NHSS30 provides an industry including the correct selection of and contractors on how to benchmark, ensuring that project equipment and its appropriate use, effectively implement and use processes are planned and use then most accidents involving falls NHSS30. properly trained and competent can be prevented. This is one of the National Highway Sector installers. It focuses on goals of the Precast Flooring Schemes (NHSS) are management continuous improvement, quality Federation (PFF) and its Code of systems that address a range of of installation and reduced Practice for the Safe Installation of topics including surface ongoing costs for both the client Precast Concrete Flooring and treatments, road markings and and supplier. Competency is Associated Components. pothole repairs. They provide demonstrated by a combination of The third edition of the Code of confidence for the specifier and Modular paving includes paving • Promoting confidence in quality knowledge and assessed Practice was published in 2013. The client in the quality of installed blocks, flags, slabs, setts, kerbs and management systems by provision installation techniques, and PFF membership remains work. Scheme 30 in the NHSS accessories manufactured in precast of a robust, transparent system. covers both rigid and flexible committed to achieving a high suite covers the installation, concrete, natural stone or clay pavement constructions. standard and universal approach maintenance and repair of ISO 9001 framework Sector schemes are included in to health and safety. It is only by modular, small element paving. National Highway Sector Schemes the procurement process through the industry showing leadership Modular paving includes are bespoke integrated reference in the Specification for and taking ownership of the paving blocks, flags, slabs, setts, management schemes within an Highway Works (SHW) and all management of risk that kerbs and accessories ISO 9001 framework. They are sector scheme documents are improvements will be made. Part manufactured in precast concrete, written by technical advisory published directly by UKAS of this activity is the provision to properly used by designers in natural stone or clay. NHSS30 is a committees made up of (United Kingdom Accreditation employees, subcontractors, discharging their CDM scheme set up to improve the representatives from across the Service) – this is available for free designers and customers of clearly obligations, then the risks of death installed quality of all types of paving sector including clients, download from its website at presented information about and injury from falls and other modular paving products by: contractors, suppliers, www.ukas.com. current best practice for the factors should be greatly reduced. • Providing an industry manufacturers, trade associations, With a number of well-known installation of all types of precast The third edition is currently benchmark training organisations and contractors already registered flooring, such as beam-and-block available and the fourth edition • Ensuring that all processes are certification bodies. under NHSS30 and further and hollowcore. will soon be available as a free planned The NHSS30 scheme document companies already undergoing A fourth edition is soon to be download from the PFF website. • Providing a basis for continuous – the secretariat for which is assessment in preparation for published to take account of the Printed copies of the fourth improvement provided by British Precast registration, it is expected that the CDM Regulations 2015 and edition will made distributed to • Focusing on quality as an affiliate Interlay, the Association of scheme will enable the small- developments in best practice. It members, training organisations objective Paving Installers – gives details of element paving industry to is needed for the growing precast and the HSE. In parallel, a print • Reducing overall costs for the training requirements for improve significantly its flooring sector – we anticipate version of an abridged pocket- client and supplier operatives and supervisors, as well installation standards. Where the increasing use of precast flooring sized document, containing the • Providing and maintaining a as information on quality plans, quality of our road installations, as systems in the upper floors of key elements of the Code of properly trained and competent NHSS30 ensures an essential requirement of ISO well as repairs and maintenance, houses as demand for quiet and By working with PFF members you Practice, will be made available to workforce that project 9001. A dedicated scheme are under scrutiny, this will help durable floors grows. can help to ensure site safety construction site staff. • Involving all sides of the document to allow registered to control costs and improve The input of the Whether you are a client, a industry in scheme ownership processes are companies to adapt their systems confidence. Industry standard Health and Safety designer or a contractor, please within a partnership framework planned and use to include the requirements of ISO The input of the Health and Safety remember that by working with • Ensuring that certification 9000:2015 is due for release shortly. For further information on the NHSS30 Executive to this fourth edition, Executive establishes PFF members you can help to bodies are used whose auditors properly trained and NHSS30 aims to improve the scheme, how it operates and where through its detailed review, it as an industry ensure safety on your sites. have technical knowledge and competent installers installed quality of modular additional guidance and support can establishes it as an industry experience of the sector paving and is supported by be found, visit: www.interlay.org.uk/ standard. As with previous standard For more information, visit concerned Interlay as well as Interpave. It nhss30 editions, if the guidance is www.precastfloors.info

28 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | | 29 Housing

The HCA has been reported as stating that public money will be used to fund land and factory Housing construction for offsite and modern methods of The planning question construction, in line with the tenor of the white paper analysis and proposals. This, however, leads to a Small sites are a solution to the housing crisis. In turn, these point to masonry construction real concern that government policy is now incentivising certain construction methods and white materials at the taxpayers’ expense – most of which are likely to lead to increased imported materials. ore houses are being built but the build rate spheres about the ‘how to build’. Benefits of masonry is still too low. That is ProPosals by HoMe builders FederaTion To increase Housing sTarTs We are again in an upcycle of talk paper The current proposals, to favour offsite and modern the consensus, if not of offsite solutions. These clearly methods of construction, fail to recognise the long- M LAND AND PLANNING the unanimous view, across the have a role to play in delivering term benefits of masonry and potentially give rise to industry and political spheres. • Altering the Definition of a Small Site our built environment and the The Modern Masonry Alliance the dangers of focusing on numbers and speed in Recent reports from those at the • Introducing a presumption in favour of residential development on appropriate brownfield sites concrete sector has many offsite place of long-term quality, durability, long life and sharp end point to a common • Increasing the ‘buffer’ required in Five Year Land Supplies solutions that can be read about raises concern about the whole-life carbon reduction. Both the Home Builders Federation and the Federation of solution – SMEs and small sites – • Planning for a wider range of sites within local plans in this supplement. Support for increased offsite construction and even Master Builders see no reason to change their support and use and a common underlying • Creating a duty to properly test actual delivery from allocated sites and plan for additional allocations where supply However, offsite solutions must government’s focus on the expenditure of public funds to provide land and of traditional construction methods which, according to the solution of planning. It is not all falls short (ongoing trajectory planning) be chosen on merit, not offsite manufacturing factories – which may stimulate greater use of National House Building Council, currently represent 80 per about materials, skills or • Changing the classification of garden land incentivised through government imported materials rather than indigenous materials – cent of the current output (90% in England). construction methods. Market • A new phased planning application fee schedule interference. In the housing sector, The Modern Masonry Alliance has outlined its needs to be questioned, particularly when local product forces will resolve these. Those in • A ‘Help to Plan’ scheme for micro-builders and start-ups such interference risks general support for the need for more housing and and labour is available that avoids the need to wait for political spheres should focus on disincentivising the masonry the Department for Communities and Local new factories to be built, and for factory workers’ skills those aspects that only they can FINANCE construction at the very time Government’s housing white paper, Fixing our broken to be developed before production can commence. resolve – such as planning, red • Government action to get lenders lending government is reliant on this housing market, which was published on 7 February. The government’s concentration on new and tape and access to finance – and • Lifting barriers for builders to access Government support enjoyed by SMEs in other sectors traditional method of build – The MMA supports the broad analysis and modern methods of construction to meet the avoid getting involved in how we • A ‘Help to Build’ scheme using government guarantees to support SME expansion NHBC statistics show only 15 per recognition of past problems limiting growth in requirement of 1 million homes within the term of this build. cent of the market is timber-frame. housing numbers in the white paper, as well as the parliament ignores the sector that currently already The Home Builders Federation RED TAPE More housing will only happen if inclusion of helpful recommendations such as the contributes over 85 per cent of current output and (HBF) published a report in • Seizing the opportunity of Brexit masonry housing output is promotion of, and aid for, small and medium-sized which has existing capacity for expansion. January 2017 titled Reversing • Earlier participation of Highways Authorities in pre-planning discussions maintained or increased itself. homebuilders. However, the white paper incorrectly The materials used for traditional construction are the Decline of Small • The use by Highways Authorities of a single set of national standards Furthermore, SME attributes delays to shortcomings in traditional locally and responsibly sourced, plentiful in supply, Housebuilders: Reinvigorating • An overhaul of the Highways Act 1980 housebuilders are familiar with construction and is misinformed as to the contribution low-cost, low-carbon and long whole-life solution Entrepreneurialism and Building • Using existing legislation to open up technical approval and supervision masonry construction and small offsite construction methods can make in terms of providers for housing. The forms of construction More Homes. In this report, • Deemed discharge of Section 38 and Section 278 conditions where Highways Authorities do not make a decision on sites lend themselves to the numbers, long-term quality and immediate delivery. currently used meet the highest ‘fabric first’ standards Redrow chairman Steve Morgan approval flexibility of design, just-in-time The need for more housing is reflected in two of for energy conservation. In addition, the benefits of said: “The principal cause of the • Resist attempts by Ofwat to give water companies free reign over the fees they charge to developers materials procurement and local the DCLG’s four strategic objectives for this thermal mass and other properties provide protection housing crisis is the decline of • The creation of a single water and sewerage infrastructure charge skills. parliament: increasing home ownership and and resilience to climate change threats such as small and medium-sized HBF: Reversing the decline of small housebuilders: Reinvigorating entrepreneurialism and building more homes, The HBF and FMB point to increasing the supply of homes, with an ambition of flooding, overheating and extreme weather events. housebuilders, which can be January 2017 SMEs and small sites being the delivering a million new homes in England by 2020. One benchmark for quality should surely be that traced back to the 1990 Planning solution, and in turn these point Projections suggest there will be at least 227,000 homeowners and occupiers of the future are able to Acts combined with the financial FederaTion oF MasTer builders’ key recoMMendaTions To deliver More HoMes: to masonry construction. new households formed each year between 2011 and be assured that their homes provide high-quality, crisis of the late 2000s”. Government should concentrate 2021. This is substantially higher than the annual healthy, comfortable and affordable accommodation The FMB published Delivering Councils should: on enabling this by addressing average of 166,000 extra homes in England over the in a quality environment capable of adaptation. More Homes through Small Sites • Seek to reduce complexity and uncertainty in the application process, through the use of coordinating codes and planning. past 10 years. Delivery of the government’s million The increase of blockwork manufacturing is in December 2016. This report also better early engagement. new homes ambition by 2020 will require 174,000 net already in hand through investment in new highlights planning as a key • Use their land assets creatively, including giving consideration to the use of direct commissioning, joint ventures and additions each year. production lines and additional working shifts, and barrier: “Our survey in this report deferred payment models. Many of the factors behind the shortage of new further measures to improve and increase skilled shows that a vast majority, nearly • Improve their strategic engagement with SME housebuilders including, where possible, by establishing developer Builders are homes are outside the control or influence of trades/training are in place. This will be aided further 90 per cent, of councils do not forums, online portals and workshops. familiar with product manufacturers. They include access to by the proposed measures to encourage small and think that the target of one • Seek to broker, where feasible, relationships between small builders and private landowners. finance and land, a range of planning issues and the medium-sized contractors back into housebuilding million new homes in England by Central government should: masonry construction fact that, up until now, delivery has been where the size of projects undertaken is most likely 2020 will be met with current • Give councils the power to set and vary planning fees locally where extra revenue can be ringfenced and good service and small sites lend concentrated within private sector housing for to favour flexible off-the-shelf masonry solutions. levels of resource in planning levels guaranteed. themselves to the purchase. There are now potentially new players that Offsite construction has hitherto been limited in departments.” • Consider establishing a pilot Small Sites Expert Task Force to develop best practice and act as a source of expert may change these dynamics well beyond the its application, needing high throughputs and advice on small sites. flexibility of design, changes proposed by the government in the white significant repetition to be cost-effective. It also Political rhetoric FMB, Delivering More Homes through Small Sites, December 2016 just-in-time materials paper – in particular, the build-to-rent sector, requires long-term certainty to attract investors for In contrast to these clear housing for the growing over-65 population and now investment in time, research, production facilities messages on needing to improve procurement and the potential re-entry of Local Authority action led and trained operatives. Masonry was – and will the planning process, there is local skills by the Homes and Communities Agency (HCA) in its always remain – the main solution and is a proven much rhetoric from political new form, Homes England. product that is available now.

30 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 3131 Housing

30 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 || 3131 Fire Resistance Housing Masonry: the first choice A sustainable solution In mitigating the risk of fire, a sensible starting point is choosing non-combustible structural materials Reconstructed stone has provided a cost-effective solution for a housing project in Gloucestershire

uilding in non- uilding materials stone roof tiles provide a viable combustible materials, “Fires in dwellings Concrete blockwork’s fire manufacturer Aggregate alternative to natural stone slates, including masonry, is performance means it is used to Industries has supplied and were supplied in a full range of naturally beneficial when of timber-framed provide the compartmentation a range of walling diminishing lengths and random B when other products are tested B considering the devastating construction and roofing products to a widths. consequences of fire. Data has Redrow development in been published by The experienced on Gloucestershire. Authentic alternative Department of Communities and average more Each of the 124 properties Aggregate Industries Building Local Government showing damage than those has been carefully designed to Products sales director statistical analysis of fires in blend seamlessly with the Jeremy Lee says: “We’ve worked completed timber buildings. The of no special surrounding landscape, with with Redrow for a number of results aren’t surprising – timber construction” homes arranged in an arc around years but this contract was buildings are more susceptible to the water’s edge, providing each particularly special to us as the fire spread than masonry Stephen Williams MP, with a southerly aspect and open build was taking place on a site buildings are. Minister for Communities views across the lake. formerly home to one of our During the construction stage and Local Government, Rough dressed walling in buff manufacturing plants. of a building project, choosing the was specified for exterior walls as a “Our products, all right materials is essential in House of Commons, cost-effective alternative to natural reconstructed stone, not mitigating any fire risk. While 22 January 2015. stone, while concrete aggregate only provide an aesthetically proper design is essential, the blocks were used for the structural authentic alternative to natural structural material chosen is build. stone but also provide an incredibly important; non- Conservation roofing tiles were incredibly cost-effective combustible masonry blocks are a specified to help meet the stringent solution.” great starting point. decisions that significantly demands of the conservation affect fire risk should consider and EnhancEd dEsign REquiREMEnts: planning area. The reconstructed www.aggregate.com No special requirements reduce the risk and consequences PRoPERty PRotEction Considering fire risk, no special of fire during the construction requirements are necessary for phase through design.” Property safety may be assumed to arise from masonry buildings during The masonry industry suggests adherence to regulations, but it does not. construction. Unfortunately, the that while proper design is Building regulations do not have any role in same does not apply for timber required – no matter what protection of property from fire beyond the buildings. While the timber structural material is chosen and stipulated period of escape and limiting spread to Precast goes up a level building frame is exposed, while workmanship is always neighbours. precautionary measures need to be important – a sensible starting Fire safety is controlled by Building Regulations taken to minimise any hazards. point in risk mitigation is to under Part B of the Building Regulations in England, Precast concrete for upper floors offers a wealth of benefits for both housebuilders and homeowners There have been numerous cases of choose non-combustible Section 2 in Scotland, Part B in Wales and Part E in timber frame fires that have started structural materials. Northern Ireland. They require appropriate early recast concrete upper Currently, the same cannot be site activities can be undertaken. smoothing out temperature gains during the construction phase, Masonry offers a cost-effective warning, means of escape and sufficient fire resistance to permit occupants floors offer benefits to said for upper floors in houses, For homeowners, precast upper and losses, thereby reducing the caused by poor trade management solution. As well as being to escape from buildings in the event of a fire, as well as measures to limit builders and homeowners which are predominantly timber. floors have several advantages over need for space cooling and heating on site, and incorrectly following responsibly sourced, local and spread of fire to adjacent properties and buildings. – and with sustainability But this could be set to change. timber. Firstly, due to its density in the home. Designers, owners and building operators should be aware of additional P set guidelines. thermally efficient, masonry offers credentials as well, designers are set precast concrete flooring is The use of precast flooring cuts The HSE has previously raised the additional benefits of acoustic guidance and recommendations for improved property protection published to be specifying them more often. Better site safety effective at reducing the down on transport and the concerns of poor management in resistance and low whole-life by RIBA in collaboration with the Fire Protection Association and In 1974, precast concrete was For housebuilders, the use of transmission of sound between associated carbon footprint. Precast reducing the risk of fire in timber carbon. RISCAuthority. It provides clear, enhanced guidance based on the principles only used in about 5 per cent of precast flooring can improve safety rooms – when did you last hear a flooring can be made locally, using buildings. There has been unease of AD B Volume 2 buildings other than Dwellings. This does include flats. the ground floors constructed for on site. There is a well-established concrete floor creak or squeak? local materials and skills, and that the necessary procedures are For further information, visit One recommendation is that for buildings comprising of a predominantly homes. However, following code of practice for the safe Secondly, the flooring is fireproof. hence travel distances from factory not being followed, further www. modernmasonry.co.uk combustible material such as wood or SIPS, the project team at the design changes to building regulations in installation of precast flooring and Precast concrete floors very easily to site are reduced. increasing the risk of harm to stage gives serious consideration to constructing the ground level from that year, precast concrete with the introduction of safety exceed a one-hour fire rating, Furthermore, by using precast occupants of neighbouring non-combustible elements as a means of reducing risk. suspended floors experienced an nets, and decking, this protecting against the spread of flooring there is no need to import buildings. The BRE Home Quality Mark also takes positive account of the use of increase in usage, to the extent that construction activity has become fire between rooms. Thirdly, materials, such as structural timber, In an open letter in October non-combustible materials as a measure of enhanced quality. around 70 to 80 per cent of all safer. In addition, precast flooring precast flooring has a high from overseas. 2014, the HSE said: “All those ground floors constructed in provides an early, secure and broad thermal mass. Employed correctly, making design and procurement houses are now precast concrete. platform from which subsequent this thermal mass can assist with www.precastfloors.info

32 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | | 33 Fire Resistance Housing Masonry: the first choice A sustainable solution In mitigating the risk of fire, a sensible starting point is choosing non-combustible structural materials Reconstructed stone has provided a cost-effective solution for a housing project in Gloucestershire

32 | 00British Month Precast 2012 www.cnplus.co.uk www.cnplus.co.uk 00British Month Precast 2012 | | 33 Housing A mature market Longley Concrete is the supplier of flooring, staircases and lift shafts for LNT’s care home developments

t cannot have passed anyone’s flooring, staircases and lift shafts attention that accommodation for two- and three-storey LNT for the elderly is a growing Precast concrete is developments. Each care home has Imarket. approximately 60 rooms as well as LNT Construction builds care the preferred building communal areas such as residents’ homes for the over-65s, allowing material for the care lounges. them to live independently in Beam and block flooring is their own private accommodation. home developments quickly installed by Longley’s In the space of over two decades, contracting team, providing an over 50 care homes have been immediate working platform for all built, offering 3,000 rooms for of the build projects. The flooring is residents. draughtproof, rot-proof and fire Precast concrete is the preferred resistant, and provides both good building material when it comes to thermal and sound insulation. the care home developments, with Longley Concrete supplying www.longley.uk.com

Thermal Bridging – is your SAP assessor making your design look as good as it is?

Achieving required or desired accurate psi values associated energy performance arises from with the actual details rather than good design and construction in default values in SAP. the following areas: U-values, air Use of these details goes a long tightness and thermal bridging at way to helping optimise fabric junctions. performance. By having details Thermal bridging is not a new with the associated psi values, issue or concept, but as the compliance can be demonstrated U-values of walls and floors has without recourse to more improved and airtightness has expensive solutions. Their use can increased, the percentage of lost also help avoid the need for energy that passes through renewables. thermal bridges has increased. Therefore it has become For more information, visit increasingly important to attend www.modernmasonry.co.uk to thermal bridges – and for SAP assessors to sharpen their pencil and not use default values. For masonry construction, design help is available through a suite of details for which psi values have been calculated (a psi An example of thermal bridging Key points: value is the measure of energy lost 2 detail. These details together with 1. The R-value of the perimeter insulation should be at least 0.8m K/W at a junction). Clients and 2. Ensure the floor insulation is tightly butted against the external wall architects should require SAP their calculated psi values should 3. Continue the cavity insulation at least 225 mm below the top of the concrete assessors to use these more be used by SAP assessors

34 | 00British Month Precast 2012 www.cnplus.co.uk Housing A mature market Longley Concrete is the supplier of flooring, staircases and lift shafts for LNT’s care home developments

Thermal Bridging – is your SAP assessor making your design look as good as it is?

34 | 00British Month Precast 2012 www.cnplus.co.uk Homes that people want to live in. Homes that last.

Masonry homes provide superior construction and in use.

Energy saving The thermal performance of concrete and masonry homes can provide homeowners with the lowest energy bills because of the superior insulation, airtightness and thermal mass. Long life Purchasing a home is a major investment and the inherent performance of concrete and masonry provides robust and secure homes that will last for many generations.

Concrete and masonry are non-combustible protecting life and property safety for occupants. During construction, these properties also protect the developer and surrounding

Quiet do not squeak: 48% of homeowner noise issues raised with NHBC for detached homes were

Flood resilient Homes built from concrete and masonry suffer less damage because they are robust, dimensionally stable and do not rot.

Contact the Modern Masonry Alliance

Housing. www.modernmasonry.co.uk @masonrymodern

Project: Derwenthope, York