MARCH 2019

Overcoming offsite risks Buyers guide Precast concrete addresses Find your concerns associated with precast offsite methods supplier p25 p14

FIT FOR THE FUTURE

SuDS Concrete block permeable paving helps meet demands for sustainable drainage p12

Sustainability In 12 years, the precast sector has reduced manufacturing carbon emissions by 28% p24 Reasons to Buy British Precast

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

UK sourced Responsibly constituent sourced materials

Over 6,000 hectares of priority habitat has been created on restored sites Over 80% of cement and 95% of aggregates are sourced from within the UK All British Precast members are signatories to our Sustainability Charter

DURABLE FIRE RESISTANT ROBUST LONG LASTING EXCELLENT ACOUSTIC/THERMAL PROPERTIES The average travel distance from factory to site is only 70 miles Reduces imports and improves Local construction the UK trade gap products

Buying British Precast Concrete Reducing imports will help to sustain the UK •construction Supports industry a UK manufacturing sector and the UK economy • Protects the jobs and livelihood of UK society • Reduces travel distances and protects our environment Use our online Buyers Guide to choose your UK construction product

A domestic Precast Sector is essential for the UK

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 - improving our schools, houses, offices, lower carbon. The UK government’s 2025 construction targets hospitals, transport networks, utilities and refer to a 50% reduction in the trade gap quality of life. Responsibly sourced precast between exports and imports for construction British Precast is part of the wider UK Mineral Responsible and ethical sourcing is easy to products and materials. Buying British Precast Products Industry which directly contributed demonstrate for products made in the UK from will help to address this trade gap and reducing to the UK economy by generating over £6.4bn UK sourced constituents. British Precast meets the import of construction products will help 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 contributed to £495bn turnover in industries construction products. industry. downstream of the supply chain. All British Precast members are signatories to our Inherent Properties of Precast The UK Precast Sector has an annual turnover Sustainability Charter. of £1.3 billion [1] and directly employs 13,000 www.britishprecast.org/sustainabilitycharter Precast Concrete has inherent benefits that people in the UK [2]. enable designers to deliver cost effective, Biodiversity and our rural economy materially efficient projects. British Precast The concrete industry makes a significant Inherent benefits include: Precast concrete and concrete blocks are contribution to biodiversity and nature • non-combustible formed from three constituents: water, cement conservation through the management and • durable and aggregates. More than 80% of cement restoration of sites of mineral extraction. • robust MPA data shows that over 6,000 hectares of is manufactured in the UK from UK sourced • moisture resistant materials. More than 95% of aggregates are priority habitat has been created to date on • inert sourced from within the UK and typically close to restored sites. the precast factory. With an abundant supply of limestone in the • rot resistant The average travel distance from precast factory UK, the manufacture of cement in the UK results • good thermal properties to project site is 70 miles - this equates to just a in a lower carbon footprint. The cement sector • good acoustic properties few hours’ drive compared to the longer journeys employs 2,000 people directly, and 15,000 indirectly in mainly UK rural areas. [4] Find out more at www.britishprecast.org [1] Facts at a Glance, Mineral Products Association, 2016 [2] Health and Safety Statistics, British Precast, 2016 [3] Sustainability Matters, British Precast, 2016 [4] Cementing the Future, MPA Cement, 2013

www.britishprecast.org/buyersguide Contents BRITISH

4-5 Creativity in Concrete British Precast has crowned Robert Bray Associates as the 2018 PRECAST Creativity in Concrete Award Winner There is much talk about the need for more housing in the UK. To this end, the government should avoid intervening 6-7 Higher levels of housing Even in these unnecessarily in construction methods, while ensuring that times of Brexit uncertainty, masonry o ers robust housing is longlasting and resilient to fi re, fl ood and solutions to the UK’s housing overheating. Masonry construction delivers the vast majority of housing 8-9 After Grenfell The Hackitt Report will bring and if an increase in housing starts is to be achieved, there will changes to building safety. What does this mean need to be more masonry construction p6. British Precast for precast concrete? members also o­ er o­ site solutions and the choice of precast can address many of the risks associated with lightweight 10-11 Speedy success British Precast member o­ site solutions p20 and p25. This edition of Construction Creagh Concrete is using an innovative fast-track News gives an insight into resilient housing and o­ site system to deliver projects manufacture through British Precast member case studies, and updates from the sector. 12-13 The future is permeable With the All Full members of British Precast sign up to the rigorous latest guidance from Interpave, concrete block Health & Safety and Sustainability Charters. Not only do these permeable paving helps meet demands for SuDS charter schemes encourage members of British Precast to go beyond legislation to improve their operations, but they also 14-15 British Precast buyers guide o­ er assurance to businesses of our initiatives to support best practice. Member concerns do not stop at the factory gate and so Find your precast supplier they provide guidance for designers, contractors and clients regarding the safe installation of their products p18. 16 British Precast Associates Resources from To fi nd a responsible supplier of precast concrete and The Concrete Centre, along with a listing of masonry, check out our latest buyers guide for Full members Ž Associate Members of British Precast shown in the centre pages of this supplement. A list of Associate members is also included p16. Our interactive guides for Full 18 Your CDM obligations Half of all and Associate members can also be found on our website at construction-related fatalities result from falls www.britishprecast.org/buyersguide. These guides o­ er an from height – but it doesn’t have to be this way e“ cient way to fi nd products and services. Alan Smith 20-21 Fit for the future Precast concrete o ers Chief Operating O cer, Brett Group a valuable opportunity to respond to the UK’s President, British Precast drive for o site solutions To fi nd a responsible manufacturer and supplier of precast 22-23 Averting a climate catastrophe and masonry, you can have a read of our buyers guide on The construction industry has a vital role to play p14 or online at www.britishprecast.org/buyersguide if we are to slow down global warming

British Precast is the trade association of precast concrete manufacturers and is a federation 24 Twelve years on including specialist product groups and sector bodies. This year marks the 12th anniversary since the www.britishprecast.org precast sector launched its fi rst sustainability British Precast is affiliated to the Mineral Products Association (MPA), the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and silica sand industries. strategy www.mineralproducts.org EMAP British Precast Telephone House The Old Rectory 25 Overcoming oˆ site risks Precast concrete 69-77 Paul Street Main Street overcomes the concerns associated with o site London EC2A 4NQ Glenfield Email [email protected] Leicestershire construction methods Printed in England by Buxton Press LE3 8DG United Kingdom

26 A helping hand Aggregate Industries plays Telephone: +44 (0) 116 232 5170 a critical role in making sure McCarthy & Stone Email: [email protected] delivers its projects

British Precast | 3 Paving: Awards Creativity in concrete British Precast crowned Robert Bray Associates as the 2018 Creativity in Concrete Award Winner

he 2018 winner of the British Precast Creativity in Concrete Award was TRobert Bray Associates. RBA has been at the forefront of Sustainable Drainage Systems (SuDS) for more than 20 years and recognises the potential of concrete block permeable paving (CBPP) as a key, multifunctional SuDS technique. RBA has made the most of permeable paving to deliver a gradual flow of clean water for amenity, landscape design and biodiversity on numerous SuDS schemes that include housing, schools and commercial developments, as well as civic and public realm enhancements. Recent projects include Australia Road, London; Bewdley School, Worcestershire Parkside; St George’s Primary School, Kidderminster and the Civic Centre, Bromsgrove. The first of these schemes – Australia Road, London – won two Landscape Institute Awards in 2017. The first award was for the Adding Value through Landscape category, while the second award was the President’s Award, also known as the ‘Winner of Winners’.

West London renewal The Australia Road urban renewal project began as a SuDS initiative by Hammersmith and Fulham Council to retrofit permeable paving into the streetscape. It introduced the innovative Clockwise from top left: Australia concept of CBPP as a thin overlay Road, London; Bewdley School, for existing highways. The CBPP Worcestershire Parkside; St George’s simply replaced the bituminous Primary School, Kidderminster; material on the original road base. the Civic Centre, Bromsgrove; The same blocks that are used in and another view of Australia permeable pavements generally Road, London were installed over a geo- composite sheet, which transports water horizontally. Rainwater is attenuated and treated within the

4 | 00British Month Precast 2012 www.cnplus.co.uk British Precast was delighted to present Robert Bray with the 2018 Creativity in Concrete Award, in recognition of his innovative work combining SuDS with hard landscape

paving and then discharged into adjacent planted basins or rain gardens. Consultation with local people led to an integrated design that linked two disconnected spaces and the paving was used to break the existing formal road alignment. The scheme also connected the Randolph Beresford Early Years Centre to an adjacent play area and generated a social hub for parents and children. Meandering through the whole space is a wiggly wall – a reminder of a low wall used as a balance beam by residents in their youth. British Precast was delighted to present Robert Bray with the 2018 Creativity in Concrete Award, in recognition of his innovative work combining SuDS with hard landscape. www.cnplus.co.uk British00 Month Precast 2012 | |5 5 Buildings: Housing Higher levels of housing Masonry offers robust solutions to the UK’s housing – even in these times of Brexit uncertainty

asonry products are While we seek to meet housing assessing the performance of new an essential set of start numbers, what is built must Masonry is homes. materials that, quite meet the need for housing that is We are confident that the Mliterally, run through resilient to fire, overheating and sourced locally, MHCLG research will conclude the fabric of society. the sustainability agenda. In manufactured locally that thermal mass has an The current media and policy masonry, designers have a product important role to play in focus on housebuilding really that can continue to deliver these and delivered locally minimising risk of overheating champions the benefits of outcomes. all around the UK. and that the change in regulations masonry products and promotes cannot come soon enough. masonry construction. Fire safety If the housing In parallel, The Good Homes Modern Masonry is a forward- The first response to Grenfell is market continues Alliance has commissioned a thinking organisation, always rightly focused on life safety and to grow, so will project and project teams to better looking towards new methods as an industry it is our duty to support local authorities in the and solutions that will have a learn, preventing such events production evaluation of overheating risk in positive impact on the masonry from happening in the future. new residential planning manufacturing industry, masonry Masonry is non-combustible applications, and to raise construction and so by and in relation to Diagram 34 awareness of possible design association, the wider UK protects life and property safety climate change (HC 826), which solutions. The guidance is intended construction industry. for occupants. highlights the relevance of for use at the pre-planning and Concerns about overheating and welcomes the planning application stages of Housing compartmentation can be promise of Ministry of Housing, construction projects. The aim is to The UK government is keen to overcome with the use of masonry Communities and Local help planners and designers to stimulate the housing market and products for partitions instead of Government’s (MHCLG) to conduct spot potentially high-risk designs, has a target of 300,000 new-build lightweight systems. research into overheating in new enabling informed dialogue and homes per year by 2025. During construction, these homes. The EAC also highlights helping to identify solutions at an Whole-life resilience is key to properties also protect the that many reputable studies are early stage if needed, for everyone’s ensure a homeowner’s major developer and surrounding available to assist designers now. benefit. The guidance will be investment is protected for community from the spread of The direction to the available in Spring 2019. generations and the inherent flame. government was clear in performance provides robust and recognising that modular housing Wise investment secure homes. Adapting to climate change is typically of lightweight Masonry housing is not limited to Modern Masonry believes that Alongside being durable and long- construction and therefore does the life of your mortgage. these benefits are often over-looked lasting, thermal mass is a key not have thermal mass, so the Directly linked to robustness in government support for benefit of masonry construction government should re-evaluate and resilience, masonry has a strategies that largely use which is therefore, key to healthy their support for “Modern positive impact on reducing unproven methods of construction. and sustainable new housing. Methods of Construction”. maintenance costs, disruption Masonry is a local and long- After one of the hottest summers Together with natural and maximises utilisation. lasting material; a strong on record in 2018, The Environment ventilation and shading, the According to the insurance foundation for a sustainable Audit Committee (EAC) released a utilisation of thermal mass is a industry, vertical floods such as solution. report Heatwaves: adapting to recognised design strategy for leaks, are the most likely water minimising overheating. damage event in housing. In Recent research, investigating terms of resilience against water A Dream Home “the impacts of overheating in damage, masonry is the best and Early in 2018, Modern Masonry conducted a survey into the aspirations of new homes on mortality and a most reliable way to build, and UK homemakers, which revealed that they value the benefits that masonry loss of productivity due to sleep even better when combined with construction can provide – such as safety, robustness and durability. disruption”, should assist the concrete floors. Masonry construction is a traditional, tried-and-tested method. It represents government in its forthcoming the vast majority of new housebuilds in the UK. We want to highlight that review of Part L of the building The uncertainty of Brexit turning to other solutions will not deliver the best build. Despite a perception regulations. This will include a To preview 2019, we need to first of other materials and methods being ‘green’ or quick to work with, or being review of the overheating consider recent historical simply more advanced because they are new, only masonry products offer assessment included in SAP, performance, next year’s forecast all-round performance qualities. which is the energy/carbon for housing starts and the specific compliance tool used by Part L for impacts of Brexit.

6 | 00British Month Precast 2012 www.cnplus.co.uk BENEFITS OF MASONRY Long life Higher levels of housing Purchasing a home is a major investment and the inherent performance of masonry provides robust and secure homes that will last for many generations. Masonry housing is not limited to the life of your mortgage. Energy saving The thermal performance of masonry homes can provide homeowners with the lowest energy bills because of the superior insulation, airtightness and thermal mass. Low fire risk Masonry is non-combustible, protecting life and property safety for occupants. During construction, these properties also protect the developer and surrounding community from spread of flame. Flood-resilient Homes built from masonry suffer less damage because they are robust, dimensionally stable and do not rot. Health Masonry exceeds minimum noise performance requirements, which Masonry has existed for a long time, so codes and standards have been means you are less likely to be thoroughly developed to meet Building Regulations disrupted and disturbed by noise through walls. Over the past five years the mothballed production lines and such as imported timber. Already number of housing starts has installing interventions into lines the timber industry is expressing increased by 78 per cent and the to maximise productivity. concern over supply, currency market share for masonry Concern about fire resilience fluctuations and overall costs. housing has been maintained at and compartmentation, as a result Therefore, it is likely that the most around 85 per cent with other of the Grenfell tragedy, is expected direct Brexit impact will be methods of construction such as to lead to the use of masonry increased demand for local timber frame and offsite modular products for partitions in masonry products from having only a 15 per cent in the commercial and non-public housebuilders who want to UK (NHBC statistics). housing projects instead of minimise costs and remove Despite uncertainty over Brexit, lightweight partitioning. Based on uncertainty. the new-build market continues previous responses to demand, There is also a social benefit as to grow, and is now accounting for the masonry sector is increasing masonry output will an estimated 15 per cent of overall demonstrably ready and able to subsequently increase local job is well under way and will housing transactions, up from a respond to both increases. opportunities. empower contractors to train long-term average of around 8 per Fortunately, the masonry sector apprentices. Statistics show that cent – a clear demonstration of is protected from much of the Skills agenda there are 70,000 skilled bricklayers the commitment of the industry uncertainty surrounding Brexit. A key partner of Modern Masonry, in the UK but with these new to deliver further growth. In fact, this uncertainty could the Brick Development training schemes, skills can It is credit to the masonry potentially end up working in the Association (BDA) is undertaking double to 140,000 manufacturers whose investment sector’s favour as masonry, an initiative alongside the On a broader note, every house to increase output has enabled a specifically blocks, are a local Construction Industry Training built supports an estimated 3.1 continuation in the building of product made from local Board (CITB) to provide half-day jobs, meaning the industry is now cost-effective and resilient housing. constituents with a short supply to two-day course on bricklaying, supporting over 700,000 jobs – This investment has been in the chain. This is in stark contrast which will be equivalent to a level almost 300,000 more than it was form of new factories, re-opening with the competitor material, 2 NVQ. Production of these guides six years ago.

www.cnplus.co.uk British00 Month Precast 2012 | 7| 7 Safety: Hackitt report After Grenfell The Hackitt Report will bring changes to building safety. What does this mean for precast concrete?

ince the tragedy of the wall, including balconies and sun- Grenfell Tower fire there shading devices. Precast concrete have been a number of is classed as non-combustible and, Sactions that have or will in addition to providing a robust affect the construction industry. external wall solution, it would In May last year the Hackitt seem the obvious solution for Report – the Independent Review balconies and solar shading on of Building Regulations and Fire the relevant buildings. It is a little Safety – was published. This report disappointing that the ban did concluded that the current not consider combustible regulatory framework was not fit structure, although it may be that for purpose and proposed a new this will come from the current regime for High Risk Residential consultation on Approved Buildings. It is expected that Document B. many of the processes proposed The Hackitt Report stated that will apply to other buildings. the use of non-combustible In November last year, the materials throughout the building government implemented a ban “provides inherently higher levels on combustible material in the of protection”. In fact, combustible external wall of residential type structures are already restricted in buildings over 18 m high. This was some parts of the UK. The Scottish done by changes to the Building Handbook 2017 effectively Regulations and an update of prohibits the use of combustible Approved Document B. In structure in residential buildings December, Approved Document B above 18 m unless a safety was updated again to significantly engineering approach is used. limit the use of “desk studies” to Concrete, being non-combustible, extend the results from fire tests can provide simple and safer to non-tested situations. Also in solutions. December, the government issued its plan as to how it will The Hackitt Report implement the recommendations While perhaps not having of Hackitt and launched a the direct impact of the consultation into the technical combustible cladding ban, the content of Approved Document B. Hackitt Report and the Here, we will look in more detail government’s commitment to at the current and proposed implementing it are likely to have changes – and specifically what far-reaching implications. The this means for precast report limited its construction. recommendations to High Risk Residential Buildings (HRRBs), The ban which it defined as residential The introduction of the ban on buildings over 10 storeys in height. combustible materials in the This building type is seen to pose external walls of buildings, with a the highest risk to life safety. storey over 18 m, applies to The recommendations that the residential buildings, care homes, Hackitt Report suggested could be only applied to HRRBs, they are building safety. In various sheltered housing, student applied to other building types in likely to be applied more widely presentations, Hackitt has noted accommodation, hospitals and due course. However, while the once processes have been that its recommendations should dormitories. Interestingly, as well systems are being developed, established. be applied to all safety elements. as applying to external walls, it prioritising HRRBs is reasonable. While the review overall was Indeed, in July 2018 the Secretary also applies to certain specific What is clear is that even if the primarily concerned with fire of State for Ministry of Housing, items attached to the external recommendations are initially safety, the report also discusses Communities and Local

8 | 00British Month Precast 2012 www.cnplus.co.uk Government announced the with recommendations of a by creating the Joint Regulators further review of a number of creation of an industry safety digital record that would include Group. This group will consist of Approved Documents to deliver a steering group to be chaired by traceability of the products used. the HSE, Local Authority Building more holistic set of guidance, as Dame Judith Hackitt, confirming The inherent fire resistance of Control, the National Fire Chiefs recommended by Hackitt. a wider remit than just fire. precast concrete provides simple Council and the Local Unfortunately, at present, that fire protection and is largely Government Association. It is does not include structure. The Joint Competency Authority defined by the main designer, thus suggested that this group would Central to the Hackitt proposals is obtaining acceptance prior to help define how any future JCA Summary the formation of a new Joint starting work, demonstrating should work. The ban on combustible materials Competent Authority (JCA) compliance. Accommodating in the external walls of the comprising Local Authority changes should be low-risk for The Building Regulations specified buildings will create Building Standards, fire and precast concrete compared to The Hackitt report calls for a opportunities for non- rescue authorities and the Health other materials. “regulatory framework featuring combustible precast concrete and Safety Executive. The JCA will There is also the proposal for clear outcomes”. The report solutions, both for the cladding be responsible for assessing the the JCA to carry out periodic effectively calls for an overhaul of and for items such as balconies project at various stages. safety reviews of occupied the Approved Documents to attached to the external wall. It is For example, prior to the start of buildings. In these reviews, the ensure a more holistic approach to important that the banning of construction, approval of the “full dutyholder will need to outcomes. The Building combustible structure in these plans” is required, noting this demonstrate that they have Regulations themselves are largely buildings is considered in the “should include the dutyholders considered, controlled and outcome-based, but the concern current consultation on Approved providing detailed specifications managed any risks that arise. expressed is that the Approved Document B. of building works in respect of fire In older buildings, damage to Documents then replace these While the Hackitt Report is and structural safety as a fire protection due to following outcome-based requirements with primarily concerned with fire minimum”. If this works, unauthorised works or prescriptive rules. safety, the recommendations are recommendation is to be applied accident is a credible risk. This is one area where likely to be more far-reaching. rigorously, it will require Effectively, the proposal is to government has not, so far, Structural safety will probably significantly earlier involvement extend CDM through to safe followed the Hackitt fall under the same framework. of specialist subcontractors, occupation. Concrete, with its recommendations with the ban of It is also likely that the particularly regarding passive and in-built, robust, passive fire combustible material being both recommendations will be applied active fire protection measures, protection, is a low risk solution highly prescriptive and written significantly wider than residential but also regarding structural after occupation. into the Building Regulations buildings over 10 storeys. details. The government has rather than just the Approved The concrete industry should Any changes to the submitted demonstrated its commitment to Documents. welcome the recommendations plans, and details of how the establishing the JCA in some form The government has launched a favouring non-combustible building’s construction materials for providing life and compliance with the original property safety. An inherent design was verified, is then benefit of concrete is that it does reviewed by the JCA and will need not burn. This should minimise to be passed prior to occupation of the risks in achieving approval to the building. There is likely to be a commence work, demonstrating greater focus on the content and compliance with the design and accuracy of as-built drawings, accommodating changes during construction, under the proposed JCA overview. The robust nature of the fire protection of concrete also means The robust nature that it is less prone to in-service of concrete means damage and therefore minimises the risks in its use. This latter that it minimises point will be important for risks in its use dutyholders responsible for managing the risks of High Rise Residential Buildings in use. www.cnplus.co.uk British00 Month Precast 2012 | |9 9 Residential: Modular precast Speedy success British Precast member Creagh Concrete is using an innovative fast-track system to deliver projects

he exclusive Forbes Place • Extremely robust structure development at • Reduced heating and Stoneywood, Aberdeen maintenance costs Tcomprises four apartment • Improved health and safety blocks: two of seven storeys and • Versatile range of finishes two of five storeys, providing a including various brick finishes total of 276 apartments. The and smooth, etched, patterned development also includes and even printed concrete underground car parking. The finishes, offering a more robust client, Dandara, turned to British and maintenance-free alternative Precast member, Creagh Concrete, to render systems to design and construct the • Pre-installed windows and patio structural frames using an doors innovative offsite fast-track • Pre-finished internal walls ready modular precast concrete build for direct decoration system, called Rapidres. • Cast-in M&E conduits and Rapidres is an example of a backboxes structural cross wall design, • Option of precast pre-finished which is ideally suited to multi- balcony units storey projects where the layout is • Excellent fire protection. replicated consistently across each floor. While most projects Precast columns & transfer will have variation of layout in beams mixed-use spaces on the ground The underground car-parking floor, this is routinely dealt with structure was designed with by the use of a structural podium, precast columns placed under the which forms the base for the cross walls above. Each set of offsite structure. columns had a transfer beam Construction speed for the total spanning across their heads, frame solution is greater than with the cross wall above working alternative systems, with as a deep beam. Brick faced significant programme savings. retaining walls were used around The build was manufactured the perimeter of the carpark offsite and took 40 weeks to structure. complete consisting of precast panels, columns, transfer beams, Flooring hollowcore flooring, internal cross For this scheme Creagh Concrete walls, lift shafts, stair flights and used 250 mm-deep prestressed landings. hollowcore concrete floor planks Benefits of the Rapidres offsite for the upper floors. A typical fast track build system include: span for a two-bedroom • Acoustic separation is apartment is 10.15 m, with no minimised due to the density of requirement for a structural the floors and walls topping. The floor slabs were • Inherent thermal mass designed with a fire rating of • Reduced overall carbon footprint 90 minutes. Lift shafts of the building, with an EPC ‘A’ Construction The precast lift shafts were class energy rating achieved Stair flights and landings speed for the total supplied in floor-to-floor height throughout Each stair core housed two flights box-type units. • Reduced site co-ordination as and two landings. The stairs were frame solution is many follow-on wet trades are supplied ready for direct greater than Walls eliminated decoration with no requirement The composite concrete wall • Reduced preliminary costs due for plasterboard or suspended alternative systems panels comprised a 150 mm to reduced programme times ceilings. structural leaf, 130 mm of

10 | 00British Month Precast 2012 www.cnplus.co.uk insulation and an 80 mm external as one complete composite 323-apartment scheme that will leaf, thereby eliminating the need concrete panel, while 210 mm feature studio, one-bed and two- to have a traditional cavity wall single-skin internal walls were bed apartments with balconies system. The insulation provided a mist-coated with white emulsion across all elevations. U value of 0.17 W/m2K and enabled paint within the factory, ready for The development is a dual- strong thermal characteristics decoration when installed. block building with a cast in situ throughout the build. The walls External wall facades were made reinforced concrete basement and arrived on site with the up of brick-faced precast ground floor featuring a mechanical and electrical (M&E) sandwich panels and white acid 1.8m-thick transfer slab that is first fix within the panels, etched concrete panels. cantilevered across the south-east together with windows and doors corner. prefabricated offsite and Replicating success The Rapidres system then completed with an internal mist Dandara was so impressed with springs from this slab, from levels coat. The M&E was incorporated the modular precast concrete 1 to 22 for the first block and from into the early stages of design and system on the successful build at levels 1 to 17 for the second block, captured in the production Forbes Place that it is now using with the two blocks linked by process for all services. A 22.5 mm the system on another residential bridges at each level. galvanised conduit was fitted by development. The Arena Central The bulk of the Arena precast Creagh Concrete’s specialist development in Birmingham’s panels measure 8 m in length, installation team. city centre is a £40m with the floor plan based on a To reduce the amount of work similar 8m grid. The units arrive onsite and to speed up Dandara was so impressed with on site from a holding point just weathertightness of the build, the Creagh’s work at Forbes Place outside Birmingham and are then uPVC windows were fitted into (below) that it used the Rapidres lifted directly into position. The the panels, sealed at the factory in system at the Arena Central project placing of each storey is based on Toomebridge and delivered to site in Birmingham (opposite page) a turnaround time of just 10 days.

www.cnplus.co.uk 00British Month Precast 2012 | | 11 11 Paving: SuDS The future is permeable With the latest guidance from Interpave, concrete block permeable paving helps meet demands for SuDS

ew legal requirements for dwellings (and similar scale serve more than one property. Above: at this Peterborough Sustainable Drainage commercial developments). The Welsh National Standards housing association scheme, roof- Systems (SuDS) on However, the Welsh Government point out that: “The SuDS water passes into permeable paved developments across has now implemented Schedule approach mimics natural driveways connected to the access N road. Opposite page: SuDS on this Wales were applied from 3 of the Flood and Water drainage, managing surface runoff 7 January of this year, heralding Management Act, which relates at or close to the surface and as high-density Stamford housing wider use of concrete block to provisions for SuDS. close to its source as practicable, complex is largely provided by permeable paving (CBPP). At the controlling the flow (volume and permeable paving without same time, the trade association Approval and adoption rate of runoff) and providing a additional land-take Interpave has published Edition 7 These measures include the range of additional benefits. It of its definitive guidance to this establishment of a SuDS contrasts with traditional essential SuDS technique – Design Approving Body (SAB) to be set up drainage techniques, which are drainage components are and Construction of Concrete within each local/unitary based on underground pipes to visible in their operation and Block Permeable Pavements – authority, alongside its lead local convey rainwater away from performance, and are generally now available to download flood authority duty. SAB approval properties as quickly as possible.” simpler and easier to operate, from the paving resource will be required before The standards continue: monitor and maintain…. Where www.paving.org.uk. construction of drainage systems “Surface-based sustainable SuDS are on the surface, high It’s over three years since the can commence on new and quality visual impact is essential government chose to abandon redeveloped sites. The to ensuring public acceptability dedicated requirements for SuDS requirement for SAB approval will CBPP technology and maximise amenity benefits.” on new developments in England not apply to single dwellings and By its very nature, concrete using the 2010 Flood and Water developments with a construction has proven itself block permeable paving (CBPP) is Management Act. Instead, the area of less than 100 m2. Provided over decades of uniquely placed to meet these National Planning Policy appropriate statutory National requirements as an attractive, Framework (NPPF) requires SuDS Standards are met, the SAB successful use in surface-based, multifunctional sustainable drainage on new will be required to adopt and the UK SuDS technique. Of course, hard developments of 10 or more maintain approved SuDS that surfaces are necessary for

12 | 00British Month Precast 2012 www.cnplus.co.uk developments anyway – whether low-cost SuDS technique. Its using terraces of compartments long-term performance with for roads, parking, shared spaces capability to attenuate water flow separated by simple check dams minimal, if any, maintenance. or play. But CBPP also provides an during rainfall for gradual incorporating flow controls. inherent drainage system that discharge is well known. But this Moreover, flow controls can be Latest guidance requires no additional land take principle is optimised for greater used to retain water and make the Interpave’s new guidance for water storage, treatment or cost efficiency by considering most of available infiltration, so document – Design and conveyance. It also addresses both distinct storage ‘compartments’ of reducing discharge. Construction of Concrete Block flooding and pollution issues by CBPP using straightforward flow Permeable Pavements – primarily storing and cleaning water runoff control devices with an orifice – Real design freedom aims to ensure that CBPP delivers at source. accurately sized and accessible for Of course, paved surfaces help predictable, robust solutions and observation or adjustment if to define the character of any to minimise cost, maintenance Lower costs needed – on the outlet. development. The growing choice and adoption issues. It is intended This technology eliminates This technique enables water of CBPP products available from for planners, urban designers, pipework, gulleys and manholes, storage to be strategically Interpave manufacturers – with engineers, local authorities and and should therefore cost less than deployed around a development numerous shapes, styles, finishes other decision makers to assist conventional drainage and paving. within permeable paving and colours – allows real design them in the design, construction, In fact, CBPP can also accept runoff compartments, each with a freedom. At the same time, approval and maintenance of from other impermeable paving flow control demonstrating permeable paving can provide CBPP on developments. and roofs, giving further savings. It compliance to local authorities a completely level, well-drained, Its scope includes the use of can simply infiltrate rainwater as part of the SuDS design firm and slip-resistance surface CBPP as a key SuDS technique but falling on it straight into approval process. It maximises accessible to all, without the it covers other types of application permeable ground, after removing the potential for water to be stored need for cross-falls, channels, as well. It deals with all aspects pollutants. But, more commonly in on site beneath paving that is gulleys or other interruptions. and stages of design, relevant to the UK, less permeable conditions needed anyway. Dedicated water Rainwater ‘ponding’ is eliminated, the various professions – such as clay – will limit storage on valuable land and reducing the risk of ice forming constituting the project design infiltration and on brownfield sites associated excavation and on the surface and preventing team, from initial master- existing pollutants may preclude construction costs are avoided, splashing from standing water. planning through to detailed infiltration. and this technique can help CBPP technology has proven design and construction, and Here, permeable paving is used satisfy SuDS requirements on itself over decades of successful finally post-construction. to collect and store water on site high-density urban schemes use in the UK and around the This latest edition includes during storms, before gradual without expensive storage world – notably in Germany since an extensive new glossary and discharge to other SuDS features structures. the mid-1980s. Experience of CBPP covers the most recent CBPP along the ‘management train’, Similar techniques maximise in use in the UK over more than techniques. The guide is freely surface water or combined sewers, storage in CBPP on sloping sites, 20 years has demonstrated its available to download via www. or watercourses. This attenuation paving.org.uk. and delayed discharge from the Representing major UK permeable paving avoids drains manufacturers, Interpave surcharging and downstream promotes and develops precast flooding. Where a comprehensive concrete paving as a modern, SuDS scheme is planned flexible and sustainable incorporating landscape features, technology for applications CBPP removes water-borne ranging from hard landscape to pollution and provides a gradual the heaviest-duty commercial flow of clean water at the head of pavements. Its new website the ‘SuDS management train’. provides an essential resource Water in open SuDS features on covering all aspects of design the surface can then be used with precast concrete paving, safely to enhance landscape including an inspirational design and biodiversity. project gallery and case studies, supported by background Improving efficiency information for all design Following long-term use in the stages, as well as CPD. UK and abroad, CBPP has proved to be a predictable, reliable and www.paving.org.uk www.cnplus.co.uk 00British Month Precast 2012 || 1313 British Precast Buyers Guide

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 Agricultural Products Arch, Portal & Box Structures Architectural Dressings Basement Units Beam & Block Floors Beams & Columns Bespoke Products Block Paving Blocks, Inner Leaf & Partition Blocks, Outer Leaf Box Culverts Bridge Beams & Gantries Cast Stone Architectural Units Cladding & Structural Wall Units Composite & Double Tee Floors Concrete Bricks Decorative Internal Surfaces Decorative Paving Dock Leveller Pits Ducts, Conduits & Markers Fencing Flags Flat Pack Systems Foundation Blocks Foundation Units & Piles Frames Garden Products Grandstands & Terracing Ground Beams Hollowcore Floors Kerbs Lighting Columns & Transmission Poles Lintels, Sills & Copings Manholes & Inspection Chambers Multi-storey Carparks Packed Products Pipes Pods Prefabricated Buildings Railway Sleepers, Bearers & Units Reinforced Aircrete Floors Retaining, Revetment & Crib Walls Road Surface Drainage Roof Tiles Sea & River Defence Units Specialised Building Systems Staircases & Stair Units Street Furniture & Bollards Tunnel Linings Vehicle Safety Barriers Water Treatment & Storage Tanks 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

14 | British Precast www.cnplus.co.uk Visit www.britishprecast.org/buyersguide for the latest 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 1. ABM Precast Solutions 2. ACP (Concrete) 3. Aggregate Industries 4. Amber Precast 5. Banagher Precast Concrete 6. Barcon Systems 7. Besblock 8. Bison Precast 9. Breedon Aggregates 10. Brett Landscaping 11. Broome Bros (Doncaster) 12. Castle Construction Products 13. CCP Building Products 14. CEMEX UK 15. Charcon Construction Solutions 16. Collier Quarrying & Recycling 17. Cornish Concrete Products 18. Craven Concrete 19. Creagh Concrete Products 20. Cross Concrete Flooring 21. Decomo UK 22. Delta Bloc UK 23. E&JW Glendinning 24. Elite Precast 25. Evans by Shay Murtagh Precast 26. Forterra Building Products 27. FP McCann 28. H+H UK 29. Hillhouse Quarry Group 30. Ibstock Concrete 31. Interfuse Blocks 32. Jordan Concrete 33. Laird Bros 34. Lignacite 35. Litecast 36. Longley Concrete 37. Mansfield Sand 38. Marshalls 39. Marshalls CPM 40. Mona Precast 41. Naylor Concrete Products 42. Newlay Concrete 43. Patersons Quarries 44. Plasmor 45. Quinn Building Products 46. Robeslee Concrete 47. S. Morris 48. Sellite Blocks 49. Skene Concrete Products 50. Specialist Precast Products 51. Stanton Bonna Concrete 52. Sterling Services 53. Tarmac Building Products 54. Techrete 55. Thakeham Tiles 56. Thomas Armstrong Group 57. Thorp Precast 58. Topflight Precast 59. Townscape Products 60. TT Concrete Products 61. 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

www.cnplus.co.uk British Precast | 15 List of British Precast Associates

Adomast Manufacturing Ltd Elkem Materials Ltd Patterns and Moulds Ltd International Partners Arcelor Mittal Euro Accessories Limited PCE Limited Canadian Precast Institute B&B Attachments Fosroc Limited Peikko UK Ltd Cement and Concrete Association BASF Construction Chemicals GCP Applied Technologies Ltd Pemat UK of New Zealand BDS Marketing Research Ltd Graceland Fixing Ltd PERI Ltd CPI Worldwide Beresford’s Flooring Ltd Halfen Limited Polarmatic Oy Concrete Manufacturers Besser Company Hanson Cement Limited Precast Concrete Structures Limited Association – South Africa Bianchi Casseforme SRL Hendriks Precon B.V Precast Construction Technology Ltd National Precast Concrete BRE Hickman & Love (Tipton) Ltd Probst Handling Equipment Association Australia Breedon Cement Ltd Huntsman Pigments Proctor Johnson Builders Merchants Federation Inform UK Ltd Progress Group National Precast Concrete Cambrian Services Inter-Minerals PUK Ltd Association USA Carbon8 Aggregates Ltd Invisible Connections Resiblock Ltd Precast New Zealand Incorporated Caswick Ltd Isedio Ltd RFA-Tech Ltd Precast/Prestressed Concrete Cathay Industries (UK) Ltd J & P Building Systems Limited Roche Manufacturing Institute CDS Curing T/A Ceramic Drying KVM Industrimaskiner A/S S&B EPS Ltd Systems Ltd Lanxess Ltd Schock Ltd Universities & Colleges Cenin Limited Larsen Building Products Sicoma SVR Doncaster College Christeyns UK Ltd Leading Edge Management SIKA Ltd Dundee College Chryso UK Ltd Leca Danmark A/S Simply Precast Accessories Ltd Kingston University ClarkeConsult Leeds Oil + Grease Co. Ltd (LOGCO) Spiroll Precast Services Ltd Loughborough University Command Alkon UK Ltd Longrake Spar Co Ltd Strusoft UK University College London Concrete Technology Ltd Low & Bonar Hull Ltd Styrene Packaging & Insulation Ltd University of Brighton Conspare Ltd Lytag Ltd T3 University of Dundee Construction Fixing Systems Ltd Mapei UK Ltd Tarmac Cement & Lime Limited University of Nottingham Construx Martek Industries Ltd Tarmac Trading Limited University of Sheffield Coote Engineering Ltd Max Frank Ltd The CPD Certification Service University of Surrey Cordek Limited Megasteel Ltd Trelleborg Pipe Seals CSM Thermomass Mentor Training Solutions Ltd Trimble Solutions (UK) Ltd University of Teesside Dywidag-Systems International Miers Construction Products ltd UK Certification authority for Reinforcing University of the West of England E3 Recruitment Moulded Foams Ltd Steels (Cares) University of the West of Scotland Ecocem Ireland Ltd N R Richards Associates Ltd Wincanton Ecoratio Europe B.V Net-Temps Ltd Yara UK Ltd EKC Systems Ltd nVent Elematic Oyj Parex Ltd Resources from MPA The Concrete Centre British Precast works with The Concrete Centre, which assists all those who design and construct in concrete to fully realise the potential of the material

The Concrete Centre offers a Brochures range of events – from free, online • Methods of construction webinars to conferences and including Offsite Concrete short courses – covering a range Construction: Benefits and of best-practice topics on Solutions, Hybrid Concrete concrete. These events are CPD- Construction and Precast certified and delivered by Concrete in Civil Engineering; technical experts and/or • Market sectors including representatives from project housing, schools, offices, teams presenting their view of hospitals, car parks and bridges; concrete exemplars. For more • Performance issues including information on forthcoming fire, flooding, thermal events, visit the events calendar at performance and thermal mass; www.concretecentre.com/events. • Sustainability including inspiration, vision and latest to Eurocode 6. Technical guidance The Concrete Centre produces a concrete and BREEAM, material exemplar projects. books include Concise Eurocode 2, range of publications. To access efficiency, concrete credentials ‘How To’ Technical Guidance Residential Cellular Concrete the full list of publications, visit and whole-life carbon. Brochures include masonry Buildings, Design of Hybrid www.concretecentre.com/ Concrete Quarterly is published documents on acoustic Concrete Buildings and publications. each quarter and encompasses performance, airtightness, flood Concrete Buildings Scheme Example titles are as follows: latest design guidance, aspiration, resilience and designing Design Manual.

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MORTAR I AIR ENTRAINING I BLOCK AND SEMI-DRY I SELF-COMPACTING SUPERPLASTICISING I SUPERPLASTICISING I WATER REDUCING PLASTICISING CDM: Guidelines Your CDM obligations Half of all construction-related fatalities result from falls from height – but it doesn’t have to be this way

very contractor, designer and client has responsibilities under If work at height is ECDM and, when it comes properly planned, to offsite construction, the Precast Flooring Federation (PFF) and then most accidents British Precast Architectural and involving falls can Structural (BPAS) have guidance that will help fulfill these be prevented obligations. Construction is a potentially high-risk activity, as it involves the use of heavy plant, cranes and personnel working at height. Falls remain the biggest cause of deaths site, storage of components, lifting Practice to accompany the full • The Code of Practice for the Safe and serious injuries in operations and work at height. The version. The pocket-sized Erection of Precast Concrete construction – UK Health and document provides information document summarises key Frameworks. Safety Executive (HSE) data for the about current best practice for the elements of the code and is Members of BPAS are past five years indicate that on installation of all types of precast intended for site operatives and combining and updating these average half of all construction- flooring, including stairs and supervisors to use when installing two documents to create a Code of related fatalities result from falls landings. precast concrete floors. Practice for the Safe Installation of from height. However, if work at The input of the Health and Structural and Architectural height is properly planned, Safety Executive (HSE) to this British Precast Architectural and Precast. The draft code of practice including the correct selection of fourth edition, through its Structural has been reviewed by HSE and this equipment and its appropriate use, detailed review, establishes it as BPAS was previously known as the highly anticipated code is expected then most accidents involving falls an industry standard. In the Architectural and Structural to be published later this year. can be prevented. This is one of the foreword to the Code of Practice, Precast Association, which was goals of both the PFF and BPAS. Chief Inspector of Construction formed when the Architectural For further information contact: Peter Baker writes: “The HSE Cladding Association and British Precast Architectural and Precast Flooring Federation continues to work closely with the Structural Precast Association Structural The fourth edition of the PFF’s Code Precast Flooring Federation and merged in 2014. Each product Tel: 0161 232 5170 of Practice for the Safe Installation endorses this guidance, which association had a code of practice, Email: [email protected] of Precast Concrete Flooring and follows a sensible and developed over 15 years ago, Web: www.structuralprecast.org Associated Components was proportionate approach to namely: Precast Flooring Federation published in 2018. The 128-page managing health and safety.” • The Code of Practice for the Safe Tel: 0161 232 5170 document covers the roles and The PFF has also produced an Erection of Precast Concrete Email: [email protected] responsibilities of key personnel on abridged version of the Code of Cladding; and Web: www.precastfloors.info

18 | 00British Month Precast 2012 www.cnplus.co.uk ® O site: Precast platforms Fit for the future Precast concrete o ers a valuable opportunity to respond to the UK’s drive for o site solutions

he UK construction construction workforce are two industry is on the cusp of issues I would highlight as being much needed critical to the future fortunes of Tmodernisation, with the construction industry. One traditional methods of could argue that the ‘stars are construction seen as unable to aligning’ and now is the time to deliver the required growth in a allow the opportunities from variety of sectors. Productivity digitisation to o set the risks of growth in the UK construction continued reliance on labour sector has been minimal over the intensive techniques.” œ1ž past two decades, with an average Government has since thrown increase of just 0.4 per cent per its weight behind a growth in year, in comparison to a 3.2 per o site construction methods. In cent increase in manufacturing. 2017, the government worked with Some in the industry believe that the Construction Leadership this is set to change and that a Council and the broader

shift to o site construction, construction sector to agree a IMAGE COURTESY OF HEXXHOME supported by new digital Sector Deal, supporting the technologies is key to meeting development and implementation known as design for manufacture core parts and components. The increasing demand. of new digital and o site and assembly ‹DfMAŽ to facilitate government believes that by Momentum behind o site manufacturing technologies. This greater levels of o site applying modern manufacturing construction methods received a Sector Deal forms part of the construction. During the approaches to building projects, it signifi cant boost from the 2016 Government’s Industrial Strategy expansion of Heathrow, four can increase productivity and Farmer Review, Modernise or Die. White Paper. separate o site manufacturing reduce waste by as much as 90 per The report concluded that we The government strategy facilities will make the project cent. For example, a school that could see a 20 25 per cent decline advocates a digitally designed set more a ordable and sustainable typically takes a year to build in the available labour force by of components that can be used by transporting assembled could be completed in just over 2026, which will necessitate a across a range of construction components in consolidated loads. four months [2]. switch to o site construction. programmes and projects. These Construction contractors are This move to a greater use of In the report, Mark Farmer said: components would be embracing DfMA by utilising digital technology and modern “The acceleration of the wider manufactured in factories and precast concrete for the o site o site methods of construction is digital revolution combined with assembled on site. Some projects prefabrication of construction also sometimes called ‘smart a shrinking traditional are already adopting what is components such as concrete construction’. fl oor slabs, structural columns, Smart construction covers a crosswall panels and beams. range of techniques with greater In November 2018, as part of the levels of activity taking place National Infrastructure and o site and increased levels of Construction Pipeline 2018, the standardisation, underpinned by government committed to digital design and engineering œ3ž. increasing the use of The fi gure produced by Bryden prefabrication and other o site Wood ‹this page, bottom leftŽ sets construction methods on public out four delivery approaches. Two projects. Details of a preferred of these methods are “volumetric” approach were published, called ‹for example fully fi tted modulesŽ ‘Platform Approach to Design for and “components”. The third type Manufacture and Assembly’ ‹P DfMAŽ.

Smart ways of thinking Adopting DfMA The ‘platform’ approach aims to facilitates greater produce a manufacturing levels of o site environment similar to the automotive sector, where di erent construction designs of car can use the same

20 | 00British Month Precast 2012 www.cnplus.co.uk The Hexxhome concept centres around a range of standardised prefabricated panels made from high strength architectural precast concrete

of smart construction is “manufactured”, which is where a precast concrete ‘platform’ approach offers the greatest opportunities to improve delivery efficiency and boost productivity. A manufactured approach enables high levels of customisation by developing and using standard components and assemblies, but follows production processes, embedding best practice from the manufacturing and automotive sectors into construction delivery. The government’s Construction Sector Deal aims to reflect a

IMAGE COURTESY OF HEXXHOME manufactured approach. The four approaches are set out in the quadrants in the diagram, together with Bryden Wood’s assessment of relative value from different approaches. Nowhere is there more of a need to utilise offsite construction than in the housing sector, where the government’s ambition to build 300,000 homes a year by the mid- 2020s is seen as unattainable with traditional construction methods at their lack of resilience to over- around a range of standardised reality to allow customers to alone and with the well-publicised heating and climate change. prefabricated panels made from visualise their homes and warnings of a skills shortage. Research conducted by Modern high strength architectural different configuration of the Masonry of the British public precast concrete. space. It also allows for easier use Resilience is key suggested that homeowners are The Hexxhome floor slabs are of BIM and for digital models to In terms of product mix, timber materially minded, with only one based on five key shapes that can facilitate maintenance and frame systems constitute the in ten wanting a timber home [5]. be put together in any deconstruction at the end of life. largest sector of the panellised This is where offsite precast configuration to create the [1] The Farmer review building systems market with a concrete really comes into its own. footprint of a pre-designed home. [2] Gov.uk: “Projects worth £600 share estimated to be around 70 It has all the attributes of solid The standardised wall panels are billion in the pipeline as per cent [4]. traditionally built homes, highly thermally efficient and can government gets Britain building: The Environmental Audit excellent thermal mass, robust be used to create almost endless Government publishes 2018 Committee has, however, quality construction and inherent configurations. This type of National Infrastructure and published concerns that fire resistance, but is also perfectly construction is sustainable and fit Construction Pipeline and Call for lightweight offsite solutions such placed to take advantage of for the future with low whole-life Evidence on Offsite Construction”. as modular timber construction digitalisation and new platform- carbon and resilience to climate [3] “Transforming Infrastructure are prone to overheating. With based methods of construction. change. Unlike other less durable Performance”. Original source: significant rises in temperature The use of precast concrete construction materials, the Bryden Wood likely in the coming decades due panel systems in housing concrete slabs and panels can be [4] “Planning and Building to climate change, there is a construction gives the benefits of unbolted and reused to form new Control Today”: www.pbctoday. serious risk to health if manufacturing without the buildings, enabling a ‘circular co.uk/news/modular- overheating in homes is not constraints of a fully modular economy’ approach to housing. construction-news/ addressed. approach. The Hexxhome system This type of platform-based modular-building/45067/ The serious problems with is one such example of ‘platform’ construction allows for the [5] Modern Masonry. A Dream predominately timber modular construction in the housing increased use of digital tools such Home: An Exploration of construction methods do not end market. The concept centres as virtual reality and augmented Aspirations

www.cnplus.co.uk 00British Month Precast 2012 || 2121 Buildings: Climate Change Averting a climate catastrophe The construction industry has a vital role to play if we are to slow down global warming

n 2018, the Intergovernmental Panel on Climate Change (IPPC) issued the most Iextensive warning yet on the risks of rising global temperatures – widely dubbed “the final call from scientists”. This warning comes from a special report by the IPCC on the impact of global warming of 1.5 deg C. The dramatic report on keeping that rise under 1.5 deg C states that the world is now completely off-track and is heading towards a temperature increase of 3 deg C [1]. Human activities are estimated to have already caused approximately 1.0 deg C of global warming above pre-industrial require ambitious actions across cement production in the UK and 81 per cent reduction in carbon levels. On current trends, global four key levers. Western Europe. emissions by 2050. Richard Leese, warming is likely to reach 1.5 The levers of change identified In the UK, efforts to decarbonise director of industrial policy, energy deg C between 2030 and 2052. in the Chatham House report are cement production are at a more and climate change at the Mineral The impact of this warming could improvements in energy advanced stage and the concrete Products Association, set out the be catastrophic, causing increased efficiency, alternative fuel use, industry has a series of importance of new technology in instances of hot weather extremes clinker replacement and carbon commitments to lower its impact the efforts to meet targets: “In the in inhabited regions, increases in capture and storage. Globally, and reports on its performance long-term, the development and flooding events, sea level rise and action on these levers has already annually. In 2014, the UK Green effective deployment of carbon irreversible biodiversity loss. delivered an 18 per cent reduction Building Council estimated the capture and storage and use of The IPPC report states that in the global average carbon total UK carbon footprint at 831Mt technology will be crucial to [5] [3] objectives to keep rising dioxide intensity of cement CO2e . In the same year the achieving the target.” temperatures below 1.5 deg C production since 1990 [2]. Much embodied carbon footprint from Research into carbon capture cannot be met through more work is needed if global UK concrete production, as technology sits alongside a government commitments in the targets on total emissions are to be reported by members of the MPA, number of important UK success

Paris Agreement COP21 alone. This met, however, especially in the was around 3.8Mt CO2e . This stories in the fight to bring down means that industry must go area of carbon capture and storage, equates to only 0.5 per cent of the emissions. Notably, the UK above and beyond to answer the which in a 2009 technology UK carbon footprint. If you look at cement sector has a very advanced call from the climate scientists. roadmap accounted for 56 per cent precast concrete production, that take up of alternative fuels. Use of

of planned emissions reductions number falls to just 1.5Mt CO2e or waste derived fuels in the UK has The role of cement to 2050. This is compared with 10 the equivalent of 0.2 per cent of increased to 44 per cent of the A recent report from Chatham per cent for clinker substitution, 24 the UK’s carbon footprint. thermal input, with waste House suggests that cement, the per cent for alternative fuels and Indeed, at the UK cement biomass fuels composing 18.3 per largest contributor to the carbon 10 per cent for energy efficiency[2] . industry level, action is already cent of the thermal input to the footprint of concrete, could The Chatham House report has focused on all four of the levers. cement manufacturing process. account for 8 per cent of global created a narrative within the The UK cement industry is a Across Europe as a whole, carbon dioxide emissions. This construction and mainstream world leader in its drive to reduce alternative fuels make up around means that in order to bring the media that in order to reduce UK carbon emissions. Since 1990, it 43 per cent of cement plant

cement sector in line with the CO2, alternatives to concrete has reduced absolute emissions by consumption compared to 15 per Paris Agreement, its annual construction should be sought. 49 per cent, with a large cent in North America, 8 per cent emissions will need to fall by at Global cement production is, proportion of this reduction in China, South Korea and Japan, least 16 per cent by 2030 [2]. On a however, very different to UK achieved through innovation and and around 3 per cent in India [2]. global level, achieving a scenario cement and concrete production. investment in efficient plant. The industry will continue to that will limit temperature The assumptions made to derive MPA Cement have also set an target lower carbon production increases to 1.5 deg C is going to the global figure do not apply to ambitious strategy to achieve an via replacing traditional fossil

22 | 00British Month Precast 2012 www.cnplus.co.uk Averting a climate catastrophe

important to remember that

emissions of CO2 associated with It is concrete cement production are also partly construction that reversible through carbonation. This is often overlooked when provides the evaluating the embodied impact resilience needed to of concrete and other cementitious materials, which future-proof our

absorb CO2 over the building buildings lifecycle and beyond. The carbonation process is the reaction between calcium oxide (CaO), an alkaline product of

hardened concrete, and CO2, which results in the formation of consideration should be resilience

calcium carbonate (CaCO3). to climate change. The ability for The decrease in CO2 per tonne of precast concrete over the past nine years The average reduction in passive temperature regulation is

embodied CO2 for structural a material choice decision that fuels; using lower carbon raw The past 10 years have seen a shift concrete is about 7.5 per cent over should all but rule out timber materials; and exploring from considering only embodied the lifecycle of a building. At end- designs. The inherent thermal innovative new technologies. capital carbon (cradle-to-gate) to of-life and beyond into secondary mass of concrete moderates MPA Cement members are all whole life (cradle-to-grave), uses, a much greater reduction temperature extremes protecting investing in a range of initiatives. including operational and end-of- ultimately occurs that can reduce against overheating in the

For example, a cement life carbon emissions. The the initial embodied CO2 by summer and reducing energy manufacturer has committed to widespread adoption of around a third. consumption in the winter. using 100 per cent renewable Environmental Production Alternative construction Climate resilience also goes electricity. Declarations (EPD), particularly materials rely on unknown further than thermal mass and those verified to BS EN 15804, is assumptions and scenarios for passive temperature regulation. Concrete action helping to make this data end-of-life impacts and emissions Buildings are also going to have to The concrete industry has made available to decision-makers. associated with landfill or stand up to increased frequency sector carbon-reduction Forthcoming changes to BS EN incineration. In contrast, and severity of storm and flooding commitments as part of the 15804 will make it mandatory to whatever the whole-life scenario events. Once again, it is concrete Climate Change Act, which legally report the end-of-life impacts of or time period considered for construction which provides the commits the UK to meeting construction products. concrete, the carbonation process resilience needed to future proof challenging reductions to The precast sector has taken a will always occur [4]. our buildings. emissions: a 34 per cent fall by lead in measuring its impact at a More sustainability data on 2020 and 80 per cent by 2050, product level through EPDs. A material fit for the future precast concrete products can be based on 1990 levels. British Precast has published The climate-conscious, including found in the annual British The data collected as part of the seven Generic EPDs at the time of the concrete industry, will fight to Precast Sustainability Matters UK concrete industry strategy writing, with a further three due keep temperature increases below publication. shows that the embodied carbon for publication. These EPDs outline 2 deg C, but the stark reality is that [1] IPPC. Special Report 1.5 of concrete has reduced by 28 per the cradle-to-grave global current trends suggest this won’t www.ipcc.ch/sr15/ cent since 1990 [3]. The precast warming potential impact of be enough. [2] Chatham House. Energy, concrete sector specifically has precast concrete products, from The construction industry also Environment and Resources

reduced CO2 emissions per tonne concrete blocks to architectural has a responsibility to produce Department, Innovation in Low- by 12.1 per cent since 2012 and is cladding. Details of these EPDs can resilient buildings because some Carbon Cement and Concrete, on course to meet its 2020 targets be found on the British Precast degree of climate change is now 2018 for carbon reduction. website at www.britishprecast. an inevitability. This means that [3] The Concrete Centre. This is One increasing trend within org/Sustainability/EPDs. the buildings we construct must Concrete – 10 years 10 insights the construction sector as a whole be suitable for a world 2 degrees [4] The Concrete Centre. Whole is an acknowledgement of the Reversing emissions warmer in just 20 years’ time. life carbon and Buildings importance on considering the When considering the whole-life When designing a building with a [5] Green Construction Board. whole-life impact of a built asset. carbon impact of concrete, it is 60-year design life, a key www.ukgbc.org/climate-change

www.cnplus.co.uk 00British Month Precast 2012 | | 23 Strategy: Sustainability Twelve years on This year marks the 12th anniversary since the precast sector launched its first sustainability strategy

he Precast Sustainability Routemap and Infrastructure Charter Scheme was first Carbon Review (ICR), have been launched, by British launched with government TPrecast, in 2007 with endorsement. In 2014, British initially 17 manufacturers taking Precast signed the ICR part and committing to a pledge commitment, pledging to reduce to address a range of the sector’s carbon emissions by environmental and sustainability 20 per cent by 2020. principles. The Charter also British Precast is also working required precast concrete on equipping the sector with manufacturers to report on 14 sufficient data and capabilities to environmental, sustainability and enable the construction industry’s economic aspects and 13 targets digitisation and zero-carbon were set for the sector to meet, challenge. Between 2015 and 2018 collectively, by 2012. Our sector we developed an Environmental rose to the challenge and met Product Declaration (EPD) tool to 12 out of these 13 targets. Not address the need for accurate and satisfied, a set of more challenging third-party verified targets to 2020 was introduced as environmental data for the part of the ‘raising the bar’ industry. Today, well over 50 per initiative. There are also other initiatives scheme. This ambitious scheme, cent of our sectors’ tonnage is Under this initiative, across the supply chain that are in place for over a decade now, covered by these EPDs. committing to the Precast improving the overall cradle-to- quantifies, and reports on, the British Precast is fully engaged Sustainability Charter became a grave environmental and social entire UK concrete supply chain with the CPA’s LEXiCON initiative, mandatory membership impacts of precast concrete performance on a number of which aims to provide consistent requirement of British Precast. products. The UK cement industry, sustainability KPI indicators. The Product Data Sheets better linking Today, all of our 65 full member for example, has reduced its SCF performance reports show the data available on precast companies (75 per cent of all overall carbon emissions by 25 per that the overall concrete concrete products to BIM models production volume in the UK) are cent since 1998. The cement sector embodied carbon emissions have We plan to incorporate a wide covered by the Charter scheme already has its own carbon road dropped by 28 per cent since 1990. range of social and ethical and are required to report map, with a target reduction in indicators into our Charter, Beyond 2020 annually on at least 14 of the CO2 emissions by 2050 of 62 per addressing issues such as modern Performance Indicators identified cent without carbon storage or 81 Despite the progress made since slavery; gender and age equality in the Charter. per cent with carbon storage. The 2007, our sector realises that more aspects; and ethics policies. We Since the Sustainability Charter aggregates, reinforcing steel and needs to be done. This year, we will also plan to update our Precast Scheme was first launched 12 admixtures’ industries have all consider objectives and targets Resource Efficiency Action Plan years ago, the precast sector has developed similar initiatives. beyond 2020. Since the last precast (REAP) to incorporate further reduced manufacturing carbon All these sectors (along with sustainability charter review in elements to enable the emissions by 28 per cent, mains precast) are members of the 2011, things have changed construction industry to water consumption by 30 per cent, Sustainable Concrete Forum (SCF), significantly. The government- achieve a circular economy. and factory waste to landfill by the concrete sustainability endorsed Strategy for Sustainable We work with a number of well over 96 per cent. Over 77 per strategy initiative and KPI Construction, launched in 2008, contractors, developers and other cent of all precast concrete was not renewed after 2012. There supply chain partners through produced by members of British is no doubt that carbon emissions, the Sustainable Concrete Forum Precast is responsibly sourced and and energy consumption, (SCF) and the REAP. We would certified to BES 6001. The sector is currently dominate the welcome their views and feedback making progress with all 2020 Overall concrete construction sustainability and on our plans for a sustainable targets and has already achieved embodied carbon environmental agenda. precast concrete product post- two of those targets: over 90 per The construction 2025 2020 and views on how precast cent of production in 2017 was emissions have Industrial Strategy, launched in concrete can contribute to covered by ISO 9001 (quality dropped by 28 per 2013, sets a 50 per cent greenhouse industry challenges such as zero- management systems) and waste gas reduction target to 2025. carbon and the circular economy. to landfill fell significantly to cent since 1990 A number of carbon-focused below 0.5 kg per tonne of product. initiatives, such as the Carbon Email: [email protected]

24 | 00British Month Precast 2012 www.cnplus.co.uk Precast: Risk assessment Overcoming offsite risks Precast concrete overcomes the concerns associated with offsite construction methods

o you want to choose be adopted by clients, designers offsite construction, but and manufacturers to try and you are conscious that address these risks. The HSE Sother members of the advises that there is a duty of care project team are wary of the risks to reduce risk through design. of being early adopters of new This can be done most effectively technology and being exposed to by choosing concrete and new suppliers. Precast concrete avoiding unnecessary fire load. overcomes the risks associated with other offsite construction Longevity during operation methods. Typical risks of offsite The durability and robustness of construction are listed below, and precast concrete also deliver a an explanation is given of how low-maintenance, long-lasting precast concrete mitigates each solution, thereby reducing risks risk. during operation and client concerns over the enduring value A local supply chain are harmonised across Europe solutions, the one-offs can be of the asset. Precast concrete is a local product. through CEN. Therefore, many created cost-effectively with The majority of precast used in precast products are CE-marked onsite in situ concrete. For Fire resistance during occupation the UK is made in the UK. This as normal practice. This enables example, an entrance in an Government statistics make clear reduces the risk to exchange rate designers and project teams to accommodation block or a foyer that timber frame solutions have fluctuation, transport problems, specify their offsite products with in a commercial premises may a higher risk of more extensive communication problems and greater confidence. This also not be suitable for factory fires. Some local authorities are difficulties in inspecting products equips contractors with the production but can be cast onsite trying to introduce information prior to leaving the factory. information to receive offsite as precast elements are installed plates for buildings that are products with the right quality elsewhere on the project. timber-framed. A responsible supply chain and performance parameters. These initiatives highlight the British Precast members provide The Eurocode suite of design Durability/robustness during problem and look to mitigate responsibly sourced products. codes by CEN with UK National construction risks, but they do not reduce the With the BRE BES 6001 scheme, Annexes by BSI have now replaced Is there a better material for ease potential wider risks to the project the British Precast Charters for the British codes. Designers can of transport and delivery to a team. The choice of non- Sustainability and Health & Safety use these Eurocodes with offsite building site than concrete, when combustible solutions reduces and all members operating under precast products because the it comes to being durable and these risks, and those of clients UK employment laws, clients can precast product standards and robust? Precast concrete does not and helps them to meet their fully address risk by choosing design codes were developed in require the same protection from CDM requirements. from the British Precast supply parallel with the purpose of being weather and its effects as chain. consistent with each other. lightweight solutions do. Overheating resilience The Zero Carbon Hub may have A robust supply chain Long lead-in Fire resistance during been wound up in 2016, but its The membership of British Precast Offsite solutions have the construction warnings to government of the is extensive, with many members disadvantage of requiring a longer The Health and Safety Executive’s risks of overheating should be producing a wide range of products. lead-in period. However, during view is clear – timber frame heeded. Responsible developers This provides project teams and this lead in period, onsite in situ solutions pose higher risks. The and informed building owners are contractors with a competitive concrete works can be carried out, timber industry, to its credit, has increasingly aware of the major supply chain. This is beneficial at such as foundations and the introduced extensive measures to risk of future overheating. tender stage and reassuring as the ground floor. In situ concrete and With the right design the project will not be reliant on any precast concrete can be designed inherent thermal mass of precast one possible supplier. and constructed together British Precast concrete is ideally suited to absorb seamlessly: same design codes, heat to reduce peak temperatures. Product standards and design same material properties and members provide This overheating risk is codes same jointing principles. responsibly sourced recognised in the building Precast concrete has long- regulations and the benefit of established standards for products Non-repetitive elements products thermal mass accounted for in the through BSI and many of these With precast concrete offsite associated SAP calculation tool.

www.cnplus.co.uk 00British Month Precast 2012 | | 25 Flooring: Residential construction A helping hand Aggregate Industries plays a critical role in making sure McCarthy & Stone delivers its projects

recast concrete flooring is widely used throughout Hollowcore the construction industry flooring units offer a Pand can play a huge role in residential construction. flexible answer to Recently, Precast Flooring flooring challenges, Federation member, Aggregate Industries, has become a trusted due to the spans and supplier to retirement living widths of units specialist McCarthy & Stone, with its precast concrete products division Charcon Construction manufactured offsite to the exact Solutions completing over 20 requirements of the designer. projects during 2017. David Thomas, category Typically, Charcon Construction manager at McCarthy and Stone, Solutions supplies and installs says: “Aggregate Industries are a 150 mm-deep prestressed concrete valued collaborative framework hollowcore flooring to ground and partner of McCarthy and Stone upper floors, together with precast and play a critical role in ensuring concrete stairs, in each McCarthy our site construction programmes & Stone building. Hollowcore remain on time and to budget.” flooring units offer a flexible and economic answer to flooring Benefits of precast flooring challenges, due to the spans and There are numerous benefits widths of units available. Each associated with the use of precast McCarthy & Stone development concrete flooring in residential will typically consist of 2,500 m2 to properties. Here are just a few: 4,000 m2 of hollowcore flooring • Flexibility of design Precast flooring offers a number of quiet homes. Additionally, precast and two to four staircases, from With their high load-carrying benefits including flexibility, rapid floors do not creak or squeak in use. ground to third-floor levels, with capacity and long spans, house construction and fire resistance • Quality variations depending upon floors in precast concrete allow Quality is of prime concern for particular developments. complete freedom of room • Rapid construction designers, developers, builders and The hollowcore floor units and layouts, with the option to use As the structural elements of the ultimately homeowners. Close precast concrete stairs are block partitions on all floor levels. floor are delivered to site ready for control of quality in all Precast use and only simple installation Flooring Federation members’ techniques are required, floors are factories ensures that quality on quickly installed ready for site is not compromised. following trades. Typically, a team • Fire resistance can complete floors of three Precast floors offer a fire houses in one day. resistance, ranging from a full half • Immediate safe working platform hour to two hours, depending on As soon as the precast elements the floor type. Where necessary, are installed, the floor can safely they can all be simply upgraded. be used as a working platform, • Ceilings and finishes allowing the inner leaf of walls Direct finishing of the soffit of and block partitions to hollowcore and beam-and-block commence. floors is possible but usually • Sound Insulation precast floors have a ceiling of Noise within the home is a major plasterboard fixed to low-cost source of concern to occupants. proprietary metal sections or to Precast concrete floors, used for timber battens, which are secured many years in the construction of with simple self-tapping anchors. flats, are now widely used in single- The floor surface can be either in occupancy housing to produce situ screed or a timber overlay.

26 | 00British Month Precast 2012 www.cnplus.co.uk

Calculating U-value and Thermal Bridging

The Concrete Block Association provides a free online U-value calculator which is designed to guide users on the choice of block and insulation combinations to achieve Go online to use our specific U-values. FREE U-value calculator - In addition, a comprehensive set of thermal bridging www.cba-blocks.org.uk construction details are free to download. These details, and their calculated heat loss values, help designers and SAP assessors to optimise projects.

The highest levels of fabric energy efficiency can be achieved with concrete block construction. Such a form of construction ensures long-term airtightness, minimal thermal bridging and gives different options for locating insulation.

Concrete blocks explained...

Concrete blocks are available Concrete blocks are made using a variety of in a range of widths. natural or man-made aggregates.

There are three basic types: • ultra-lightweight • lightweight • dense 215mm 190mm

140mm All types deliver low cost solutions for homes and buildings. 100mm They also deliver: 90mm 75mm • fire/flood resistance Typical • good acoustic performance Typical Compressive thermal Block Type density strength • durability conductivity kg/m3* N/mm2 • thermal mass that helps keep you cool in W/mK* summer and warm in winter. Ultra-lightweight 850 3.6 - 7.3 0.28

Lightweight 1400 3.6 - 22 0.60

Dense 1900+ 7.3 - 40 1.33

*Consult manufacturer for density and thermal conductivity values. Website: cba-blocks.org.uk