Lean and green precast
www.britishprecast.org lean and green precast caseUSERS study AND USERSSPECIFIERS AND SPECIFIERS OF REINFORCING OF REINFORCINGSTEEL STEEL OR OR CONSIDER CARES PRODUCOR T CERTIFICATION CONSIDER CARES PRODUCT CERTIFICATION Verified compCliancONSIDe with BrERitishCAREStandaSrdsPRODUCAssurancTe of CE on-RTIFICgoing complATIONiance of every delivery Verified compCliancONSIDe with BrERitishCAREStandaSrdsPRODUCAssurancTe of CE on-RTIFICgoing complATIONiance of every delivery VerifNoied needcompC forliancONSID fuertherwithtBrestingERitishCAREStandaNoSrdsneedPRODUCforAssuranccertificaTetofes CE on-RTIFICgoiAvngoid complunnecessaATIONiancery ofsieveryte dela deliveryys Full traceabilitNo needy of forsteel fur fromther t steelesting milltoNositeneedFulforlcbaerctifkiingcatofes CARAvESoiindcasesunnecessaof complairy sitentsdelatoyssuppliers FullVeritracfeabilitNoied needcompy of forliancsteel fuer fromtherwitht steelBrestingitish miStllatondaNositerdsneedFulforAssuranclcbaerctifkiingcaetofes on-CARgoiAvESngoiind complcasesunnecessaiaofnccomplaiery ofsieverytentsdela deliverytoyssuppliers Full traceabilitNo needy of forsteel fur fromther t steelesting milltoNositeneedFulforlcbaerctifkiingcatofes CARAvESoiindcasesunnecessaof complairy sitentsdelatoyssuppliers Full traceabilitNo needy of forsteel fur fromther t steelesting milltoNositeneedFulforlcbaerctifkiingcatofes CARAvESoiindcasesunnecessaof complairy Bsiodytents copydelato foryssupplie flanel rs Full traceability of steel from steel mill to site Full backing of CARES in cases of complaiin herents xxxxxxto supplie xxxx rs xxxx Body copy for flanel in here xxxxxx xxxx xxxx
Editor James Smith Contributors James Smith James Smith James Smith James Smith James Smith Sub-editors Fabric to BS 4483 Bar to BS 4449 Fabric to BS 4483 Bar to BS 4449James Smith Fabric to BS 4483 Bar to BS 4449James Smith Fabric to BS 4483 Bar to BS 4449Designer FabricNOW to BS 4483 CONSIDER NON-CARES PRODUCTSBar to BS 4449James Smith NOW CONSIDER NON-CARES PRODUCTSEditor in chief NOW CONSIDER NON-CARES PRODUCTSJames Smith NOW CONSIDER NON-CARES PRODUCTSGroup director HIGH RISK HIGH RISK HIGHJames Smith RISK HIGH RISK HIGH RISK HIGH RISK that non-CARESHIGH approved steel RISK will not have been that traceabiHIGHlity of steel RISK from source to that the steelHIGHA widvertisingll not cons RISKistently meet the that non-CARESfully assessed approved to the steelBritish w Stillandardsnot have been that traceabisitelit isy ofnon steel existent from source to thatrequ their steelementsD wieputyll ofnot the regional cons Britistisenth Standardsly meet the that non-CARESHIGH approved steel RISK will not have been that traceabiHIGHlity of steel RISK from source to that the steelHIGH will not cons RISKistently meet the fully assessedHIGH to the Br RISKitish Standards HIGHsite is non existent RISK requirementsHIGHmanagers of the Brit RISKish Standards that non-CARESfully assessed approved to the steelBritish w Stillandardsnot have been that traceabisitelit isy ofnon steel existent from source to thatrequ their steelements will ofnot the cons Britistisenth Standardsly meet the that non-CARES approved steel will not have been that traceability of steel from source to that the steelJames will not Smith consistently meet the fully assessed to the British Standards site is non existent requirements of the British Standards fully assessed to the British Standards site is non existent requirementsJames of S themith British Standards Commercial WHY TAKE THE RISK? SPECIFY CARESdirector WHY TAKE THE RISK? SPECIFY CARESJames Smith WHY TAKE THE RISK? SPECIFY CARES WHY TAKEFor THEfurther information RISK? about CARES SPECIFY please contact:- CARES UK CARES, PeFormbroke further House, information 21 Pembroke about CARES Road, please Sevenoaks, contact:-Kent TN13 1XR UK CARES, PeFormbroke further House, information 21 Pembroke about CARES Road, please Sevenoaks, contact:-Kent TN13 1XR 2 Telephone:www.britishprecast.org 01732UK CARES, 450000Pe Fax:mbroke 01732 House, 455917 21 PembrokeE-mail [email protected] Road, Sevenoaks, Kent Website:TN13 www.ukcares.com 1XR Telephone: 01732 450000For Fax: fur 01732ther information 455917 E-mail about [email protected] CARES please contact:- Website: www.ukcares.com Telephone: 01732UK CARES, 450000PeFor Fax:mbroke fur 01732ther House, information 455917 21 PembrokeE-mail about [email protected] CARES Road, please Sevenoaks, contact:-Kent Website:TN13 www.ukcares.com 1XR UK CARES, Pembroke House, 21 Pembroke Road, Sevenoaks, Kent TN13 1XR Telephone: 01732UK CARES, 450000Pe Fax:mbroke 01732 House, 455917 21 PembrokeE-mail [email protected] Road, Sevenoaks, Kent Website:TN13 www.ukcares.com 1XR Telephone: 01732 450000 Fax: 01732 455917 E-mail [email protected] Website: www.ukcares.com Telephone: 01732 450000 Fax: 01732 455917 E-mail [email protected] Website: www.ukcares.com foreword lean and green precast
elcome to the credit Wcrunch special issue of the Construction News Precast Supplement. We are delighted for the second year to present this for the general readership of Construction News but also for the visitors to Futurebuild and Ecobuild. Once again we are pleased to support these two excellent adjoining events. Our main problem is to decide which one to locate in – both are particularly suited to the way that our industry is developing. With at least another 18 months of tough times ahead, especially in housing, now is the time to rebuild and reposition our offer to the client, designer and contractor. 08 In these pages you can find some pointers, but to really explore what precast concrete can offer please published by emap inform (A division get to know us more. of emap limited), greater 17 22 Contact me if you want to london house, hampstead discuss together the solutions that road, london nw1 7ej for british precast, masonry and precast can provide 60 charles street, – we will be pleased to supply a leicester, le1 1fb speaker or to come and meet you. construction news: If you want to get closer still please editorial projects join us – British Precast has a manager, jennifer membership category to suit your palmer-violet (020 7728 4929); account manager, position in the supply chain and maria gonzales (020 7728 importantly to suit your pocket. 4608); CN EDitor, nick 04 lean, green precast 19 high voltage edwards (020 7728 4628) machine ThermoneX case study Martin Clarke, chief executive British Precast’s Sustainability Charter british precast: [email protected] chief executive, martin is continuing to attract new members 20 echoing success / clarke (0116 253 6161); speed reading marketing manager, 06 innovate and prosper Trent Concrete and Buchan case studies chrissie walton Opportunity knocks for those with different (0116 222 9849) ideas 21 handed on a plate / paving the way cover design: carla pryce 08 kit for the future H+H and Brett case studies quotes on the cover extracted from the little Turning precast concrete into an art form green book of concrete, and changing perception 22 in symphony / published by british new spaces precast 10 lessons in precast AltusGroup and Composite case studies concrete february 2009 Use of precast in the education sector 23 behind bars / up the wall 13 directory / buyers’ guide Buchan and Maccaferri case studies Members, associates and products 24 more than you see 17 retaining costs / Product groups: how cladding, structures, pioneering success flooring and masonry are surviving the 24 Forticrete and Structherm case studies downturn
www.britishprecast.org 3 lean and green precast sustainability Lean, green precast machine
Martin Clarke, chief executive of British Precast, reports on how sustainability in precast is moving forward through the sharing of knowledge and commitment of member companies
ncreasingly, the concrete have been working hard with The signing formed the climax with the National Construction industry is being seen as our colleagues in cement and to a one-day workshop led by College and the support of Proskills. Ihaving a key role in delivering ready-mixed concrete to deliver Jonathan Porritt and Forum for The recession poses its own sustainable construction. I am a unified approach to the market the Future. Our first report will challenges to training budgets delighted to say, that with our and to Government – an approach be published next month and and clients, so the focus will be ‘More from Less’ sustainability that recognises our commonality will set out the roadmap that on value, relevance and payback. strategy just completing its but also our differing attributes. lies ahead. Together we are determined that fourth year, we are leading the The vehicle we have created Four working groups are all aspects of sustainability will way within the cement and is the Concrete Industry focussing on all the objectives be taken forward and will not concrete sector. Sustainable Construction Forum, of the pledge. British Precast is be allowed to become victims of Throughout this period we a group of companies and trade pleased to be leading the group these hard times. have had excellent leadership bodies that, in July, signed an on education and training. from our Doctorate student important agreement whereby Particular focus is on setting up Responsible sourcing Ian Holton and colleagues at we agreed to work together to a new structure of sustainability During recent months we have Loughborough University. some stretching sustainability skills training where we plan to been working hard to develop In the last 12 months we goals between 2008 and 2012. roll out trial courses in the spring guidance to the new BRE
New Sustainability Charter members sign up
4 www.britishprecast.org standard BES6001 on Responsible industry and examination of Wirand® Fibres Sourcing of Materials. This was the priorities and concerns of its achieved by the target deadline primary stakeholders. of December 2008. Our members Since the charter was are able to tap into the experience launched on 29 November, 2007, of BRE and our staff to gain 18 companies have made a Small things accreditation and those much formal declaration to adopt the sought-after ‘eco points’ under principles into their normal the Code for Sustainable Homes. business and working practices. that make a Good progress has been Those recognised as ‘Charter made in the first year of our Signatories’ are: Sustainability Charter launched n Aggregate Industries big di erence at the end of 2007. The aim of the n Bell and Webster Precast Sector Sustainability n Brett Landscaping and Charter is to encourage member Building Products companies of British Precast to n Buchan Concrete Solutions go beyond legislation and take n Carter Concrete voluntary actions to make their n Coltman Precast Concrete products and operations more n Cornish Concrete Products sustainable. n FP McCann In order to meet this aim, a set n H+H UK of sustainability principles has n Hanson Building Products been developed based on the key n Litecast sustainability issues facing the n Malling Products precast industry. These were n Marley Eternit identified by British Precast n Marshalls following consultation with the n Milton Precast n Roger Bullivant n Tarmac Building Products n Trent Concrete To ensure that signatory companies are complying with the spirit of the charter and taking voluntary actions to improve their performance on sustainability, British Precast has developed a set of performance requirements against which They may only be the size of paper clips but companies are to be audited. Maccaferri Wirand® steel and polymer reinforcement Audit purposes fibres make a big difference to poured concrete slabs, ‘Charter Member’ status will sprayed concrete linings and pre-cast components. be awarded to those companies demonstrating the required r improved tensile strength r reduced shrinkage level of commitment across a cracking broad range of issues, and will r signi cant improvement be reviewed bi-annually. in impact resistance r improved freeze/thaw The results of the first round r enhanced re protection durability of audits will be announced this properties year. Initial indications are that companies are finding the audit process a useful way of sharing Maccaferri. Over 25 years’ worldwide experience knowledge and identifying in bre reinforced concrete technology. potential areas for improvement, and that there are some clear sustainability ‘champions’ in the industry. 01865 770555 A set of E: [email protected] sustainability principles has been www.maccaferri.co.uk developed based “on the key issues facing the precast industry”
www.britishprecast.org 5 lean and green precast innovation Innovate and prosper
Thinking outside the concrete box is the future and now is the time to act, says British Precast chief executive Martin Clarke
hen this recession judge the new markets and the data from completed is over in a year or foresight to innovate. structures, they can even Wtwo, the construction For the precast producers, this warn of overloading. Readable industry will be very different period is a great opportunity to tags can contain vast banks from the one that dived build the product and service of data and drawings over the cliff in spring 2008. portfolio for future market n Photoengraving – by using When we start to invest need. ‘Construction solutions’ retarding techniques, precast again in the new homes and is an overused term but that is components can carry renewed infrastructure that the what the precast and masonry detailed photographic images country desperately needs, the industry has to provide. n Fabric reinforcement – the key players will be unfamiliar. The winners will be those that use of textile fabrics opens up Friendships and networks add more value to the concrete the prospect of a new will have gone, and there will – value for the client, for the generation of thin tough be many new names around. tenant, for the insurer. That sections Finance sources will have means thinking well beyond n Ductal and Ceracem – not changed. Russian and Chinese precast concrete as a material. yet seen in Britain other than investors may have arrived big- in books and presentations. time. Clients’ priorities will have Seize the moment These ultra high performance been reassessed. Attitudes to In the last few years, great strides concretes give precast a direct product specification will have have been made in applied entry to new markets for A piece of translucent concrete in a moved on. concrete technology. Several much thinner reinforced tiled wall visibly proves itself For construction product key developments are ripe for sections makers, the priority during these exploitation and this is the n Translucence – no architect tough times must couple cost right time in the cycle to grab can resist the appeal of for centuries. Moreover, self- control to an informed change them; after all, much of the cost translucent precast concrete, cleaning concrete helps to programme so that market of invention and development as yet little seen in the UK reduce nitrous oxide fumes in opportunities can be maximised has been incurred already. n Self-cleaning precast – the urban environments. in the upturn. Here are just six of the best: addition of titanium dioxide The 2009 British Precast There will be winners and n Radio frequency means that concrete surfaces innovation award is now open for losers in the process, and the identification devices – RFIDs can remain free of dirt and entries and will be announced at chances are that the winners buried in benign concrete microbial growth. White the awards lunch on 12 May in will be those with the ability to can feed back performance concrete will stay white Leicester.
health and safety record continues to improve
British Precast’s Concrete Targets 2010 Scheme channelled flexibly into three core areas: physical and reportable accidents have reduced by more than pledges to reduce RIDDOR reportable accidents safety, occupational health and human factors, 65 per cent to date. and lost time by a minimum of 50 per cent in five which allows them to react to any situation that The Four Star Scheme was a response to the years, with an overriding goal of zero accidents. requires a rapid industry focus. Government-led initiative Revitalising Health and To achieve these ambitious targets, the 29 The HSE supports the scheme along with Lord Safety, and the CT2010 Scheme falls in line with member companies taking part are encouraged to Hunt of Kings Heath, former minister for health the HSE’s Target Zero approach, launched in 2005. share health and safety information within their and safety and Dr Elizabeth Gibby, HSE director Scheme members are recognised at an annual own companies and hold regular committee for the Injuries Reduction Program. The CT2010 Concrete Targets Awards dinner. In addition to meetings. They are required to submit health and Scheme continues to back the HSE’s campaigns. bronze, silver and gold titles, an award ‘Seal’ is safety statistics to the scheme administrators The HSE also supports the scheme’s Special given to those whose performance in accident every six months. Data includes RIDDOR Working Groups, which are set up for specific reduction has matched or exceeded the scheme’s reportable accidents and major injuries, chronic projects, such as the work commissioned to targets. injuries (an injury that occurs but cannot be improve the securing and covering of loads. The CT2010 Scheme also honours the valuable associated to a specific event), time lost due to The CT2010 Scheme succeeds British Precast’s contributions of individuals and small teams by accidents, subcontractor reportable accidents original Four Star Scheme which ran from 2001 to the presentation of an Outstanding Contribution and HSE enforcement notices. 2005 and resulted in a 45 per cent reduction in to Health and Safety award, which is available Members’ experiences and learning points are RIDDOR reportable accidents. The current throughout the year. included in British Precast’s Safety Alerts, which scheme, launched in 2006, reports on almost 20 are sent out to the industry. Their activities are per cent more employees than its predecessor, n www.concretetargets.com
6 www.britishprecast.org innovationcase study lean and green precast
www.britishprecast.org 7
AD380_CN SUPPLEMENT_outlines.indd 1 17/02/2009 09:31:54 lean and green precast art forms Kit for the future Thought that the boundaries for precast concrete had been stretched as far as they could? Think again, writes Paul Thompson
o the engineer, concrete is our designs for my Masters. Then a utilitarian commodity, when we set up the business, Tto the general public it is everyone seemed to want the that grey stuff on the outside of concrete products,” he says. buildings, and to others it is a The company, which beautiful material for sculpting commenced exclusive production into art forms that improve the three years ago, supplies a range urban environment – and look of sectors including commercial, Decorative leaf detail on a rather good. retail and local authorities and Kit Kaboodle commission James Armstrong falls into the counts some big names among latter group. As director of British its client base. Precast member company Kit It created bespoke polished have demanded,” he says. “The People have Kaboodle, the former sculptor concrete and glass benches, problem is by doing that our and furniture maker has a plinth and sinks for the launch of workload is inconsistent, it seems a rather odd different take on concrete’s trendy eatery Wahaca in Covent to be either feast or famine and in perception of advantages. Garden, London. The success of this market we need to iron that “People have a rather odd that project led to work for the out a little,” he says. concrete” perception of concrete,” he says, Westfield shopping centre branch Those products will be made “james armstrong, “but they will readily accept that of Wahaca in Shepherd’s Bush. at the company’s workshop in Kit kaboodle a terrazzo tile is beautiful. All we Islington Council is another Peckham, south London, using do is take that beauty and apply it repeat investor. techniques and mixes honed admixtures that work alongside in three-dimensional form.” over the years. The beauty of this the different aggregates that can Kit Kaboodle’s bespoke Expanding the range product and casting is that the be specified. Superplasticisers products are light years away Mr Armstrong is happy that designers are able to incorporate help improve the workability of from standard structural precast the company is well enough different aggregates and the mix while an anti-foaming concrete or even architectural positioned to focus on the bespoke admixtures without worrying agent helps to improve the precast. Not bad for a venture nature of its products but admits too much about its structural surface finish. Acrylic polymer that started almost by accident that there may be an adjustment performance. admixtures help ensure the after Mr Armstrong studied the to provide an off-the-shelf range. The innate strength of concrete can cure before it dries use of concrete for his Master of “In the past we have concrete is normally enough to out, particularly in the thinner Arts in Furniture Design. concentrated on bespoke work withstand most loadings on its sections. “I looked at using concrete in because that is what our clients products although Mr Armstrong does admit to using glass fibre Bespoke solutions reinforcement for notably slender With Islington Council sections. already on its client list, Mr “If there is any need to talk Armstrong is happy that the about a product’s structural urban regeneration and public performance we seek advice from landscaping sectors will help his specialist engineers. We can use business through the downturn. a variety of aggregates, including “We are a little quieter at the recycled. Everything is wet cast moment than we have been in into rubber moulds which are the past, but we still have good set upside down so that we fill order books. We make a high- from the bottom ensuring we end product normally specified get really clean top faces. on large projects, which are “The whole thing is then insulated a little from the rest of mechanically vibrated so that the the market. final finish is extremely sharp,” “That said, if anyone is looking Neckton stools, designed by Zaha he says. to trim costs we are often among Hadid, were manufactured for The mix contains a tried the first things to be looked at,” Established and Sons and tested complex array of he says. 8 www.britishprecast.org
case study lean and green precast
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It’s a piece of the pie that contractors are increasingly cutting up for the precast plate. Paul Thompson looks at how the Government’s investment in the school building programme is affecting the sector
overnment spend in the schools sprouting up around the systems with designers and supplier. Does that plus the long- education sector has always country. architects happy to specify it. term benefits of using precast Gbeen seen as a bit of a fillip And with a new band of funding Julian Taylor, technical director concrete start to outweigh the to contractors. A pat on the back in place that will ensure a similar at structural precaster Hanson initial costs? by local authorities in the form growth for primary schools, the Structherm, says: “Primary Steve Parker, manufacturing of a six-week bonus project to Primary Capital Programme, it schools are generally designed director at Buchan Concrete be fitted in at a scramble during seems increasingly likely that as single or two-storey buildings Solutions, adds: “There is little the school holidays, rather than contractors will be sent back to with a relatively simple roof doubt that our biggest material a serious sector to which serious school. structure. competitors in this sector are time and effort should be devoted. The precast concrete industry “They are designs that precast those of steel and timber. But ever since the Government is well placed to take advantage can easily build. There are not too “There is a belief with architects unveiled its multi-billion pound of this rich seam of work and many primary school designs and clients that precast concrete school renovation programme, has been making inroads into that can’t be built using precast is not the answer. We have to get Building Schools for the Future, the sector through the increased concrete.” in early to convince them.” education has been eyed specification of structural precast The secondary schools sector differently. systems. could do better, he concedes, but Enhancing performance The cash injection has The new-build primary school in order to achieve this there Education authority clients transformed the build market in particular has seen has to be greater involvement at needing to be convinced of using programme with new secondary a surge in the use of precast an earlier stage by the precast
Elementary precast use: Medlock Primary School, Manchester, Architects a Buchan Concrete Solutions project and clients believe precast concrete is not the “answer. We have to convince them” steve parker, buchan concrete solutions
precast concrete seems strange – the Government has set targets that all its new buildings must reach the ‘Excellent’ standard under the BRE’s Environmental Assessment Method, BREEAM. The use of recycled aggregates, low wastage during production, high quality manufacture, local employment and reduced delivery mileage are all plus points. Not least, its inherent thermal mass – the ability to act as a heat store, absorbing heat from the sun during the day and releasing it during the cooler evening – makes the specification of structural precast concrete a solution to achieving BREEAM excellence. “By using precast sandwich panels you are effectively 10 www.britishprecast.org Further advantages: New sports Hall, De ferrers Technology College, Burton-upon-Trent building yourself a great big structure would be a last resort. across the country. working close to live schools.” storage heater,” says Mr Parker, To really future-proof buildings, The experience of using these That speedy delivery of “and studies have shown that these long-term requirements systems should filter through to classrooms is still seen as the children perform better when should be discussed at the earliest their increased specification for essential driver to a project. And the classroom temperature is point possible during the design school building. it is why some education sector more consistent.” stage. “I think main contractors are clients still call for the use of the The outstanding acoustic more familiar with the use of outdated prefabricated portable performance that precast Model sectors precast and we are seeing that classroom inched into position concrete buildings possess is There are other key areas where they understand the advantages on a spare section of school another beneficial factor for structural precast concrete playground. school construction. systems have made significant There are not But the last word should come Use of precast is hamstrung inroads during recent years: hotel from the true client, in this case a little by the notion that building, the custodial sector, too many it’s those who use the classrooms it is inflexible and cannot care homes and the residential primary school every day, the teachers and accommodate potential amends market. pupils. Mr Parker is quick to to structure, a theory dismissed With housebuilding set to be designs that can’t champion their feedback. by Mr Taylor. in the doldrums for a couple of “be built using “Teachers love it, as do the “If we are involved early years, the education sector is one children,” he says. “They like enough then the requirements where precasters are looking to precast concrete” the fact that they can be heard for future changes are easier to gain as much market share as julian taylor, hanson easily and not drowned out by accommodate,” he says. “New possible. structherm noise from adjoining classrooms schools built from precast can be It helps that main contractors and the constant temperature reasonably easily modified, it’s have become a little more relaxed much more now,” continues Mr encourages high attention simple enough to cut via a precast about using precast systems Taylor. “With precast, it is easy to levels. member.” as their use becomes more get the building up very quickly “Our best sales representatives But cutting through the commonplace on building sites indeed, that is important when are head teachers.”
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N Precast Rooms – manufactured off-site and delivered on-site ready for final EXCELLENT FIRE RESISTANCE preparation and decoration N Wide Span Flooring – the adaptable solution that will accommodate future flooring plan alterations within a building N Insulated Wall Panels – clad in a variety of finishes; provide a strong, durable, energy efficient and fire resistant external walling solution
Bell & Webster Concrete Limited Alma Park Road, Grantham, Lincs. NG31 9SE T (01476) 562277 F (01476) 562944 [email protected] www.eleco.com/bellandwebster 12 www.britishprecast.org members lean and green precast Directory
1 ABM Precon 11 Coltman Precast Concrete 22 Glandel 32 Milbury Systems 43 Techrete Ollerton Road, Tuxford, Newark, London Road, Canwell, Beacon Hill Lane, Off Wareham The Long Barn, Tickenham Feldspar Close, Warren Park NG22 0PQ Sutton Coldfield, B75 5SX Rd, Corfe Mullen, Bristol, BS21 6RY Way, Enderby, LE19 4SD T: 01777 872233 T: 01543 480482 Wimbourne, BH21 3RX T: 01275 857799 T: 0116 286 5965 abmeurope.com coltman.co.uk T: 01202 697282 milbury.com techrete.com glandel.co.uk 2 Acheson & Glover Precast 12 Cornish Concrete 33 Milton Precast 44 The Marble Mosaic Precast Head Office, Products 23 H+H UK Milton Regis, Sittingbourne, Company Tullyvannon, BT70 2HW Point Mills, Bissoe, Celcon House, Ightham, ME10 2QF Winterstoke Road, Weston- T: 02885 568441 Truro, TR4 8QZ Sevenoaks, TN15 9HZ T: 01795 425191 super-Mare, BS23 3YE acheson-glover.com T: 01872 864808 T: 01732 886444 miltonprecast.com T: 01934 419941 cornishconcrete.co.uk hhcelcon.co.uk marble-mosaic.co.uk 3 ACP (Concrete) 34 Monier Risehow Industrial Estate, 13 CPM Group 24 Hanson Building Sussex Manor Business Park, 45 ThermoneX UK Flimby, Maryport, CA15 8PD Mells Road, Mells, Products Gatwick Road, Crawley, Delcon House, T: 01900 814659 Frome, BA11 3PD Hanson House, 14 Castle Hill, West Sussex, RH10 9NZ 65 Manchester Road, acpconcrete.co.uk T: 0117 981 2791 Maidenhead, Berkshire, SL6 4JJ T: 01293 618418 Bolton, BL2 1ES cpm-group.com T: 01628 774100 monier.co.uk T: 01204 559551 4 Aggregate Industries UK heidelbergcement.com/hanson thermonex.co.uk Bardon Hall, Copt Oak Road, 14 Creagh Concrete Products 35 North West Pre Cast Markfield, Leicestershire, 152 Great North Road, 25 Kit Kaboodle Holmfield Works, Garstang 46 Thorp Precast LE67 9PJ St Neots, PE19 8EJ Unit 5, Print Village, Road, Preston, Apedale Road, Chesterton, T: 01530 816600 T: 02879 650500 58 Chadwick Road, PR3 6AN Newcastle-under-Lyme, aggregate.com creaghconcrete.com London, SE15 4PU T: 01253 790444 ST5 6BN T: 020 7639 0323 nwprecast.com T: 01782 561155 5 Barcon Precast 15 Decomo UK kitkaboodleconcrete.co.uk thorpprecast.co.uk Unit 12A, Horwich Loco 180-186 Kings Cross Road 36 Robeslee Concrete Industrial Estate, London, WC1X 9DE 26 Lakeland Concrete Southbank Road, Kirkintilloch, 47 Townscape Products Horwich, Bolton, BL6 5UE T: 020 7689 8058 Products Glasgow, G66 1UA Fulwood Road South, Sutton T: 01204 690088 decomo.be Lakeland Pavers, North Lakes T: 0141 775 2677 in Ashfield, NG17 7JZ barconprecast.co.uk Industrial Park, Flusco, Penrith, robeslee.co.uk T: 01623 513355 16 Ebor Concretes Cumbria, CA11 0JB townscape24.com 6 Bell & Webster Concrete P.O. Box 4, Ure Bank, T: 01768 483617 37 Roger Bullivant Alma Park Road, Ripon, HG4 1JE lakelandconcrete.co.uk Walton Road, Drakelow, Burton 48 Trent Concrete Grantham, NG31 9SE T: 01765 604351 on Trent, DE15 9UA Private Road No 3, Colwick T: 01476 562277 eborconcrete.co.uk 27 Litecast T: 01283 511115 Industrial Estate, Colwick, eleco.com Pool Road, Nuneaton, roger-bullivant.co.uk NG4 2BG bellandwebster.co.uk 17 Evans Concrete Products CV10 9AE T: 0115 987 9747 Pease Hill Road, Ripley, T: 02476 356161 38 Sandtoft Roof Tiles trentconcrete.co.uk 7 Brett Landscaping & DE5 3HZ litecast.co.uk Belton Road, Sandtoft, Building Products T: 01773 748026 Doncaster, DN8 5SY Salt Lane, Rochester, evansconcreteproducts.co.uk 28 Longley Concrete Floors T: 01427 871200 ME3 7SZ Ravensthorpe Road, Thornhill sandtoft.com T: 01634 222188 18 Flynn Concrete Lees, Dewsbury, WF12 9EF brett.co.uk Products UK T: 01924 464283 39 SCC Tilley Lane, Windmill Hill, longley.uk.com Kenwood Road, Off Station 8 Buchan Concrete Hertsmonceux, BN27 4UU Road, Stockport, SK5 6PH Solutions T: 01323 832334 29 Malling Products T: 0161 432 7700 Kings Lane, Byley, flynnconcreteproducts.ie Fiddlers Reach, Wouldham scc.co.uk Middlewich, CW10 9NB Road, Grays, RM20 4YB T: 01606 843500 19 Forticrete T: 01375 486300 40 SLP Precast buchanconcrete.com Bridle Way, Bootle, L30 4UA laingorourke.com Hamilton House, Battery Green T: 0151 521 3545 Road, Lowestoft, 9 Carter Concrete forticrete.co.uk 30 Marley Eternit NR32 1DE Britons Lane, Beeston Regis, Station Road, Coleshill, T: 01502 587322 Sherringham, NR26 8TP 20 Foxon Bros. B46 1HP slp-eng.com T: 01263 823434 (Concrete Products) T: 01675 468400 carter-concrete.co.uk Coventry Road, Broughton marleyeternit.co.uk 41 Stanton Bonna Concrete Astley, Leicester, LE9 6QD Littlewell Lane, Stanton by 10 Collier & Henry Concrete T: 01455 282287 31 Marshalls Dale, Ilkeston, DE7 4QW (Floors) F: 01455 285712 Landscape House, T: 01159 441448 Unit 2, Mellors Road, Trafford Premier Way, Elland, HX5 9HT stanton-bonna.co.uk Park, M17 1PB 21 FP McCann T: 01422 312000 T: 0161 872 8410 Knockloughrim Quarry, marshalls.co.uk 42 Tarmac Building chcfloors.com 3 Drummand Road, Products Magherafelt, BT45 8QA Millfields Road, Ettingshall, T: 02879 642558 Wolverhampton, WV4 6JP fpmccann.co.uk T: 0800 121 8218 tarmac.co.uk
www.britishprecast.org 13 lean and green precast buyers’ guide
comCOpanyMPANY 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 Foundation Units & Piles Retaining, Revetment & Crib Walls Sea & River Defence Units Pipes Tunnel Linings Box Culverts Manholes & Inspection Chambers Water Treatment & Storage Tanks Road Surface Drainage Kerbs Flags Block Paving Decorative Paving Vehicle Safety Barriers Lighting Columns & Transmission Poles Street Furniture & Bollards Bridge Beams & Gantries Railway Sleepers & Units Walling Blocks, Inner Leaf & Partition Walling Blocks, Outer Leaf Concrete Bricks Architectural Dressings Cast Stone Architectural Units Lintels Sills & Copings Beam & Block Floors Hollowcore Floors Composite & Double Tee Floors Staircases & Stair Units Basement Units Roof Tiles Cladding & Structural Wall Units Beams & Columns Frames Flat Pack Systems Multi-storey Car parks Grandstands & Terracing Specialised Building Systems Agricultural Products Fencing Ducts, Conduits & Markers Garden Products Arch, portal & box structures Dock Leveller Pits Pods Chimney Systems Packed Products Reinforced Aircrete Floors Foundation Blocks Ground Beams
1 ABM Precast Solutions 8 Buchan Concrete Solutions 14 Creagh Concrete Products 21 FP McCann 2 Acheson & Glover Precast 9 Carter Concrete 15 Decomo UK 22 Glandel 3 ACP (Concrete) 10 Collier & Henry Concrete 16 Ebor Concretes 23 H+H UK (Floors) 4 Aggregate Industries (UK) 17 Evans Concrete Products 24 Hanson Building Products 11 Coltman Precast Concrete 5 Barcon Precast 18 Flynn Concrete Products uk 12 Cornish Concrete 6 Bell & Webster Concrete Products 19 Forticrete 7 Brett Landscaping & 13 CPM Group 20 Foxon Bros. Bulding Products (Concrete Products)
14 www.britishprecast.org coCOmpanyMPANY 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 PRODUCTS Foundation Units & Piles Retaining, Revetment & Crib Walls Sea & River Defence Units Pipes Tunnel Linings Box Culverts Manholes & Inspection Chambers Water Treatment & Storage Tanks Road Surface Drainage Kerbs Flags Block Paving Decorative Paving Vehicle Safety Barriers Lighting Columns & Transmission Poles Street Furniture & Bollards Bridge Beams & Gantries Railway Sleepers & Units Walling Blocks, Inner Leaf & Partition Walling Blocks, Outer Leaf Concrete Bricks Architectural Dressings Cast Stone Architectural Units Lintels Sills & Copings Beam & Block Floors Hollowcore Floors Composite & Double Tee Floors Staircases & Stair Units Basement Units Roof Tiles Cladding & Structural Wall Units Beams & Columns Frames Flat Pack Systems Multi-storey Car parks Grandstands & Terracing Specialised Building Systems Agricultural Products Fencing Ducts, Conduits & Markers Garden Products Arch, portal & box structures Dock Leveller Pits Pods Chimney Systems Packed Products Reinforced Aircrete Floors Foundation Blocks Ground Beams
25 Kit Kaboodle 32 Milbury Systems 39 Scc 46 Thorp Precast 26 Lakeland Concrete Products 33 Milton Precast 40 SLP Precast 47 Townscape Products 27 Litecast 34 Monier 41 Stanton Bonna Concrete 48 Trent Concrete 28 Longley Concrete Floors 35 North west Pre cast 42 Tarmac Building Products 29 Malling Products 36 Robeslee Concrete Company 43 Techrete 30 Marley Eternit 37 Roger Bullivant 44 The Marble Mosaic Company 31 Marshalls 38 Sandtoft Roof Tiles 45 Thermonex uk
www.britishprecast.org 15 lean and green precast associates
ADVANTAGE PRECAST CATHAY PIGMENTS GRACELAND FIXING LANXESS ROCKWOOD UNIVERSITY OF T: 01723 871432 (UK) T: 01480 471696 T: 01283 714200 PIGMENTS (UK) PAISLEY dysonconsultingengineer. T: 01332 371759 lanxess.co.uk T: 01782 794400 T: 0141 848 3000 co.uk cathaypigments.com GRS BAGGING rockwoodspecialities. paisley.ac.uk T: 0870 111 80 11 LEADING EDGE com AGGREGATE CHOMARAT grsbagging.co.uk MANAGEMENT UNIVERSITY OF INDUSTRIES COMPOSITES T: 0118 979 7800 SIKA SHEFFIELD PACKED PRODUCTS T: +33 (0)4 75 29 81 00 HALFEN-DEHA lead-edge.co.uk T: 01707 394444 T: 0114 222 2000 T: 01530 510066 chomarat.com T: 01582 470300 sika.co.uk shef.ac.uk aggregate-uk.com halfen.co.uk LOUGHBOROUGH CHRISTEYNS UK UNIVERSITY SIG CONSTRUCTION UNIVERSITY OF AINSCOUGH CRANE T: 01274 393286 HANSON PACKED T: 01509 263171 ACCESSORIES SURREY HIRE christeyns.co.uk PRODUCTS lboro.ac.uk T: 0117 301 3610 T: 01483 300800 T: 01257 473423 T: 01628 774100 sigscp.co.uk surrey.ac.uk ainscough.co.uk CHRYSO UK hanson.biz LYTAG T: 01327 707976 T: 01904 727922 SKAKO A/S UNIVERSITY OF ARCELORMITTAL chryso.com HAARUP UK lytag.net T: +45 63 61 61 00 TEESSIDE STEEL KENT WIRE T: 01386 834016 skako.dk T: 01642 218121 T: 01634 830964 CIVIL AND MARINE haarup.co.uk MACCAFERRI tees.ac.uk kwil.co.uk T: 01708 864813 T: 01865 770555 SKANSKA heidelbergcement.com HEWDEN CRANE HIRE maccaferri.co.uk CONSTRUCTION UNIVERSITY OF THE BASF CONSTRUCTION T: 0845 60 70 111 T: 01483 758820 WEST OF ENGLAND CHEMICALS COMPOSITE hewden.co.uk NATIONAL PRECAST skanska.co.uk T: 0117 965 6261 T: 0161 794 7411 T: 02380 645700 CONCRETE uwe.ac.uk basf-cc.co.uk composite.co.uk HICKMAN & LOVE ASSOCIATION SPEEDWELL (TIPTON) – AUSTRALIA REINFORCEMENT VAN ELLE BERESFORD CONSTRUCTION T: 0121 557 2191 T: +61 8 8178 0255 T: 0114 246 7551 T: 0845 630 8993 FLOORING SYSTEMS hickmanandlove.co.uk nationalprecast.com.au speedwellreinforcement. van-elle.co.uk T: 01335 345111 MARKETING UK co.uk beresfordflooring.co.uk T: 01246 853528 HOBSON FORD NATIONAL PRECAST WALDECK csm-uk.co.uk ASSOCIATES CONCRETE SPRINGVALE EPS ASSOCIATES BESSER T: 01449 760728 ASSOCIATION – USA T: 0191 217 1144 T: 01529 415909 T: 01892 617050 CONSTRUX hobsonford.co.uk T: 317 571 9500 springvale.com waldeck-associates.com besser.com T: +32 8932 8855 precast.org construx.be ICI PAINTS TARMAC PACKED WINN & COALES BETON FORM T: 01753 550000 NEILSOFT PRODUCTS (DENSO) T: 01233 662277 CPI WORLDWIDE ici.com T: 01582 455559 T: 0800 1218 218 T: 020 8670 7511 betonform.co.uk T: +49 2236 962 390 neilsoft.com tarmac.co.uk/tarmac denso.net cpi-worldwide.com INDITHERM BRC SPECIAL T: 01709 761000 PCE TDG PRODUCTS DAVID BALL GROUP inditherm.co.uk T: 01827 301020 T: 0800 0288 834 T: 01785 222288 T: 01954 780687 pce.co.uk tdg.eu.com brc-special-products. davidballgroup.co.uk J & P BUILDING co.uk SYSTEMS PEIKKO UK TEKLA UK DONCASTER COLLEGE T: 01844 215200 T: 01325 318619 T: 0113 307 1200 BRE CENTRE IN T: 01302 553553 ww.jandpbuildingsystems. peikko.co.uk tekla.com INNOVATION don.ac.uk com CONSTRUCTION PREMIER ERECTION TRELLEBORG MATERIALS DUNDEE COLLEGE K LIFT SERVICES FORSHEDA T: 01225 388388 T: 01382 834834 T: 0800 389 5646 T: 01827 254770 PIPE SEALS UK bath.ac.uk dundeecoll.ac.uk k-lift.co.uk pes.uk.com T: 01629 813835 trelleborg.com/ BURLEYWOOD EBAWE KINGSTON PRINZING GMBH pipe-seals T: 01332 553111 ANLAGENTECHNIK UNIVERSITY T: +49 73 44 172 0 burleywood.co.uk T: +49 3423 6650 T: 020 8547 7809 prinzing-gmbh.com UK CERTIFICATION ebawe.de kingston.ac.uk/cism AUTHORITY CANADIAN PRECAST PROBST HANDLING FOR REINFORCING PRESTRESSED EKC SYSTEMS KOBRA MOULDS & LAYING SYSTEMS STEELS CONCRETE INSTITUTE T: 01924 411604 T: +31 113 562 460 T: 01939 235325 T: 01732 450000 T: (613) 232 2619 concrete.elkem.com kobragroup.com probst-gmbh.de ukcares.co.uk cpci.ca ELKEM MATERIALS KUKA AUTOMATION PUK UNIVERSITY OF BATH CARRINGTON WIRE T: 0800 068 9010 & ROBOTICS T: 01789 206800 T: 01225 388388 T: 01422 372372 materials.elkem.com T: 0121 585 0800 pukservices.co.uk bath.ac.uk carringtonwire.com kuka-robotics.com FOSROC UK QATAR PRECAST CO UNIVERSITY OF CASTLE CEMENT T: 01827 262222 KVM INTERNATIONAL T: +97 4 460 3772 DUNDEE T: 08456 001 616 fosroc.com T: 01332 825800 T: 01382 383000 heidelbergcement.com kvm.dk RAMPF FORMEN dundee.ac.uk GRACE T: +49 7391 505 0 CASWICK CONSTRUCTION LAFARGE CEMENT UK rampf.de (THE) UNIVERSITY OF T: 01427 872017 PRODUCTS T: 0845 812 6400 NOTTINGHAM caswick.com T: 01925 824824 lafargecement.co.uk RESIBLOCK T: 0115 951 5151 uk.graceconstruction. T: 01268 273344 nottingham.ac.uk com LAFARGE resiblock.com AGGREGATES T: 0844 561 0037 lafarge-aggregates.co.uk
16 www.britishprecast.org case study lean and green precast Retaining costs Forticrete wastes no time in applying its Keystone system to a high maintenance incineration facility in Slough
modular retaining wall are pultruded pins that have a restricted access as it is close to system has created a simple high shear strength and will last a railway line and the incinerator Aand economic solution for the life of the wall. building so there was no room Grundon Waste Management. The combination of Keystone for shuttering or craned-in Forticrete’s Keystone system units, positive pin connection systems. Keystone proved the is providing access to the first and soil reinforcing geogrids floor offloading level of the new enables retaining walls to be built Keystone’s £100 million waste incineration up to 12 m. The Keystone system facility at Colnbrook, Slough. also carries a BBA certificate for inner The Keystone retaining wall roads and bridges. strength is matched system is aesthetically appealing, Keystone’s inner strength easy-to-install and economical, is matched by its aesthetic by its aesthetic replacing cast in-situ retaining capabilities: combining classic “capabilities” walls. lines, graceful curves, shadows In this instance, the Keystone and textures. most economical solution for Compac units were used to On this project, it was contractor Edmund Nuttall. construct an access ramp to the important that the access ramp It is built from the top of a wall facility, which deals with over walls complemented the facade within its own footprint giving 400,000 tonnes of waste a year. of the main incinerator building a construction speed of up to 40 Keystone incorporates a – and this is where Keystone sq m of finished wall per day – high-strength fixing system to stepped up with the Splitface there are no delays from the securely lock the components in finish. completion of the face of the wall place. At the centre of the system In addition, the site had to the subsequent backfilling. Pioneering success Structherm’s rapid, flexible method exceeds Building Regulations standard at Park Central
tructherm has worked in we encouraged Crest Nicholson programme – water tightness partnership with Crest to use Structherm Fastbuild to is achieved earlier allowing SNicholson and Optima construct the apartment blocks. internal fit-out to begin sooner Community Association to build We’re not afraid to be pioneers.” than anticipated. five apartment blocks at Park Structherm Fastbuild is a And overall construction time Central, a large regeneration rapid, flexible building system can be reduced by an average of 40 site in Birmingham. It applied that consists of prefabricated per cent, which leads to savings insulated render to a number of structural concrete panels and a in preliminaries and overheads. buildings, with more planned. method of fixing, using special The overall Ecohomes rating Optima Community Association brackets and channels. There of the Park Central blocks is has used Structherm Fastbuild are endless design options and ‘Good’. All of the blocks built on three previous projects close it is suitable for many areas of using Fastbuild have achieved to the Park Central site. application, accommodating considerably higher acoustic The firm’s development manager most buildings up to seven results than the Building Dave Thompson says: “From the storeys. Regulations standard. start, Optima tried to follow the There are also many different Egan principles of partnering, package options available with the Overall recycling materials from system, from a ‘wall only’ package construction dismantled tower blocks, trialing through to a full structural shell modern methods of construction including lift shafts, stairs, time can be reduced and measuring costs against floors, roofs and balconies. by an average of traditional methods. The Fastbuild system provides “In the modern methods trials benefits that include savings on “40 per cent” www.britishprecast.org 17
lean and green precast case study
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!"#!"$ "$% &$%'$ '&( )))'!"$ "$% &$%'$ '&( ! 18 www.britishprecast.org !"#!"$ "$% &$%'$ '&( )))'!"$ "$% &$%'$ '&( ! !"#!"$ "$% &$%'$ '&( )))'!"$ "$% &$%'$ '&( ! case study lean and green precast High voltage ThermoneX sends in the troops for unusual overground operation at East Midlands train station
120-tonne crane with slew The contract is a departure standard products such as stairs restrictors was used by from ThermoneX’s usual work – and retaining walls.” AThermoneX’s team of ex- building precast basements for ThermoneX had an interesting British Army Gurkha’s to lift 26 new houses. year in 2008: building its biggest bridge parapet units into position The Bolton-based company single project – an underground – over the line at East Midlands use a lightweight thermally car park in Edinburgh; supplying Parkway station. insulated concrete to create living and installing the first contract The three-day operation space underground. It has built for Tiam – an innovative flood happened during daylight hours hundreds of basements using defence system at a Ministry of under the watchful eye of Birse X-Concrete which was developed Defence site in Sheffield; setting Civils and Network Rail. in Sweden, but has the backing of up a production facility for box Birse project manager Martin a BRE certificate. culverts and winning a contract Black says: “As far as we know “We are trying to diversify our to supply specialist flooring units this is the first time such an product range,” says ThermoneX for Bourne Parking. operation has been undertaken marketing director Michael “We are a small but flexible over a live railway.” Edwards. company offering design, supply The bridge units, cast at “We can now offer a wide and installation services,” adds ThermoneX’s precast factory in range of bespoke products to the Mr Edwards. “We can often react Shropshire, formed part of the construction market including quickly to a customer’s challenge East Midlands Parkway station lift shafts, flood defence systems, and our precast team are very to servecpc 78 East 190x132 Midlands 20/5/08 airport. 16:21box culvertsPage 1 as well as more flexible.” COLTMAN PRECAST CONCRETE. BUILD ON OUR STRENGTHS.
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www.britishprecast.org 19 lean and green precast case study Echoing success Trent Concrete’s all white for Sunderland regeneration project
ario Minchella Architects The £800,000 contract covered loved the curved white 2,200 sq m of acid-etched white, Mprecast exterior of City reconstructed stone cladding of Gate in Newcastle. So it specified 260 units. The variety of units the material for its £38 million fell into six main categories: new build, Echo 24, a high- under-window panels, spandrels Speed quality apartment development incorporating balconies, curved in Sunderland. spandrels, L-shaped spandrels, But it wasn’t just aesthetic flat storey-height panels and beauty the firm wanted to curved storey-height panels. reading achieve. Given the city centre Echo 24 has been a key location, it required speed of improvement in the regeneration installation, acoustic insulation of Sunderland’s river quarter. Modern connection methods streamline and durability – all traits of Trent Dominating the city’s skyline, Concrete’s precast cladding. Echo 24 comprises car parking, library in Milton Keynes Architect Mario Minchella two commercial units and says: “When we saw the product 179 luxury apartments over 11 on City Gate we knew it would floors. he efficiency of precast Beam supports be right for Echo 24 because concrete is influenced Columns supporting beams can we needed a product that Tby the methods used to use a projecting billet or corbel as offered clean, crisp lines, good connect or support the individual a seating. These, however, project weathering performance and elements. So, three of the most beyond the line of the column, excellent acoustic properties to popular innovations were used causing problems and increased minimise traffic noise.” for the frame, floors and stairs costs in the casting process. The result was a high quality of the Jenny Lee Library in They are also difficult to disguise finish that also simplified Milton Keynes, which houses the visually in the finished state. integration with other materials, Computing, Maths and Institute of By using Norwegian beam/ such as curtain walling. Educational Technology faculties. column connectors known as Trent Concrete managing BSF, Buchan was able to produce director David Walker says: “It’s Column shoes slender columns with no wonderful to work on a job that Traditionally, precast columns outstands. It incorporated vertical has resulted from an architect’s used to have a steel base plate, ‘letter boxes’, which accepted the recognition of a previous project incorporating starter bars and corresponding support blade in of ours. having holes for the holding the ends of the beams, resulting “Not only is it a testament to down bolts. Frequently, the base in very clean lines. precast concrete, but it gives us all plate is larger than the column a great sense of job satisfaction, section, causing problems with Landing supports too.” the mould. Precast landings can be supported At Jenny Lee, precast contractor by a variety of methods. But most It’s wonderful Buchan used Pfeifer column of these project below the landing to work on a shoes to fix the columns to their and need to be visually disguised bases. The ‘shoes’ are effectively as well as fire protected. job that has mini column bases, each one The use of RVK slab supports, resulted from accepting a single holding-down another Norwegian product, meant bolt. With starter bars already that the soffits of the landing “recognition of a attached, they weigh a fraction were clear of any visible support. previous project. of a large base plate, making Being cast into the landing, and handling in the factory easier subsequently grouted up, the It’s a testament to and safer. inserts were fully fire protected. precast concrete” The use of ‘shoes’ also allowed This support can also incorporate the slender columns to be cast resilient material to minimise david walker, without any obstructions within transmitted impact sound trent concrete the mould. (stepsound).
20 www.britishprecast.org case study lean and green precast Handed on a plate H+H’s new generation of products for the thin joint system means building with aircrete is now even faster
ulti Plates are large format specifically for use with H+H build fire-resistant internal aircrete components for UK’s thin layer Celfix mortar. The leaves of cavity external walls, Mcommercial, industrial accuracy of the units ensures that separating and other internal and housing markets, recently little or no levelling is required as walls in both load-bearing and developed by H+H. Multi Plates are laid. non load-bearing situations. The 100 mm thick H+H Multi Additionally, the use of thin They are a productivity- n Excellent fire, frost and Plates come in a standard face layer mortar and the bigger enhancing option offered as sulphate resistance size of 610 mm x 375 mm for building component means that whole-wall solutions that can be n Strength and durability, optimised build speed. Each a high level of airtightness can be priced to include installation by yet lightweight for easy handling Multi Plate weighs less than achieved. This helps to improve an approved contractor. n Thermal mass 20 kg, which allows safe manual the energy performance of the Combining superior build n Environmental credentials handling in accordance with HSE building when used in external speed with the inherent – using up 80 per cent waste guidelines. walls or provide enhanced advantages of aircrete, the Multi material in its manufacture, Manufactured to extremely acoustic insulation for separating Plates’ main qualities are: as well as providing Green tight dimensional tolerances, walls. n Excellent thermal and Guide A+ rated construction Multi Plates are supplied Multi Plates can be used to acoustic insulation solutions. Paving the way Brett’s response to Government initiative guides rain off the block
s our urban footprint impermeable surfacing material, Local Authority Planning grows, the amount of without making allowances for permission is now required for Agarden land available to controlling water runoff. the use of traditional materials, soak up rainwater reduces. As it The guidance recognises such as standard designs of block stands, only five per cent of the that the combined effect of paving or tarmacadam. rainwater which falls on urban paving over many front gardens The Brett Omega Flow land is absorbed naturally. This increases the risk of flooding, permeable paving system is one compares with 95 per cent on as most urban areas were not solution. It works on the basis rural land. designed to cope with increased of a gap formed between the The majority of rainwater in rainfall. individual blocks that allows towns and cities is channelled In addition, as the rainwater water to be channelled into into old and inadequate drainage passes quickly into the drainage the underlying porous strata systems. This isn’t helped by the system and onto local waterways, for temporary storage, storm growing trend for hard surfacing it can carry pollutants such as oil attenuation and subsequent of domestic gardens. and petrol. dispersal to the ground or And, as more garden land is From 1 October last year, the collection. lost, the strain on the drainage hard surfacing of more than 5 The Brett Infiltration System, system increases, adding to the sq m of domestic front gardens consists of permeable paving risk of flooding. is only a permitted development laid on top of open graded To combat this, the where the surface is permeable, or aggregates. Government has issued guidance where water runoff is controlled However, while permeable on the permeable surfacing of within the property through paving or soakaways avoid front gardens, which relates to the use of a soakaway or rain allowing the water to enter into changes to the General Permitted garden. the drainage system, there may Development Order. A soakaway is a ‘hole’ in, or still be issues with the type of This effectively cancels the adjacent to, a hard surface that soil. A simple soil permeability right to pave over the front allows water to filter down test, which Brett’s technical garden of a domestic property through the soil. A rain garden is a advice service offer, will reveal with any reasonable-sized area of soakaway featuring vegetation. the suitability.
www.britishprecast.org 21 lean and green precast case study In symphony
AltusGroup casts a shadow on Philadelphian condominium with its thin, beautiful panels
he 31 storeys of Symphony slab where they were mounted, House, a $125 million, and on the rest of the reinforced T163-unit condominium in concrete structure. Philadelphia, feature CarbonCast Furthermore, the thinness of Architectural Wall Panels that the panels and reduction of the provide a traditional facade and, structure provided more interior notably, a 50 per cent weight floor space and better apartment reduction of precast. layouts. This reduction proved As requested by the architect, beneficial. The restrictive the precast panels were building site necessitated a fabricated with a red-pigmented, tower crane to lift the 770 exterior sandblasted finish for a brick-like appeal, but without the expense The thinness or limited colour range of actual of the panels brick. The seven to 10-inch thick and reduction of the cladding panels enabled deep structure provided reveals, recessed planes and deep window recesses that help cast “more interior floor the shade and shadow on the space” facade. The CarbonCast Architectural panels into place, but as the Cladding Panels were designed, CarbonCast panels weigh only manufactured and installed by 18.1 kg per sq ft, they were easily AltusGroup. Its member company, accommodated even at the more Chomarat, provides C-GRID, a distant corners of the building. carbon fibre grid technology that In addition, the lightweight enables CarbonCast to be lighter, panels reduced load on the floor stronger and more durable. New spaces Repeat business for Composite as another supermarket car park is completed
he new branch of Wm single columns centrally placed Morrison Supermarkets in in the half landings, and framing TGranton, Edinburgh has a to support a travelator. precast concrete, single-deck car In addition, 28 precast concrete park as constructed by specialist ‘scorpion-tail’ columns, spanned contractor Composite. by tensioned cables, feature The 82,500 sq ft supermarket around the perimeter. Some is part of The ForthQuarter, precast concrete spandrels have one of Europe’s most ambitious been clad with granite tiling. waterfront development projects. This is the fourth car park Composite’s 5,284 sq m clear the firm has built for the chain. span car park has 246 spaces on Composite managing director the ground floor and 199 on the Roy Nield-Dumper says: “We suspended deck. As well as the were delighted to have been main precast concrete frame, it asked to work with Wm Morrison has two stair flights supported on Supermarkets again.”
22 www.britishprecast.org case study lean and green precast Behind bars Buchan returns to Staffordshire prison for high strength extension works
uchan’s crosswall method 150 mm thick, reinforced with of constructing multi- two layers of mesh. Internal Bunit accommodation walls are cast vertically in steel has been used extensively in battery moulds and following prison build for the last decade. the minimal on-site finishing, The system, used for are ready for decoration. houseblocks, segregation units External walls are cast flat, and associated buildings at over the trowelled surface being that 20 different prison sites, has been of the cavity face, while floor implemented at HMP Dovegate, slabs are generally of solid, wet- Staffordshire, an extension for cast construction with tight Skanska. tolerances that do not require a The 260-cell, two-storey, four- screed. winged K-shaped houseblock The units are high strength, is an addition to the original low water/cement ratio, low 800-cell prison built by Buchan permeability concrete for which seven years ago. elevated temperature curing The design was carried out in- can be employed. And they are house using Tekla for Precast, a produced dry, which has the Building Information Modelling advantage of low shrinkage when system, specifically configured installed on site. for cellular wall construction. The erection period lasted 19 The advantages of the system construction allowed all follow- The 3D modelling allows weeks, when up to two crawler are many when compared on trades to commence work the production of mould and cranes and two mobile cranes with alternative construction almost simultaneously. reinforcement details, which were in operation at any one methods, notably in-situ The product quality, robustness of are linked to the overall time erecting 1,758 precast concrete. structure and the obvious security model allowing alterations to units and roof steel. Buchan’s Door frames, window grills, benefits combined to produce automatically change these input included the assembly of electric conduits and boxes are a relatively maintenance-free details. ground beams, roof steelwork all cast within the concrete wall extension with good fire resistance, All walls are a minimum and purlins. and floor units. The speed of acoustics and longevity. Up the wall Maccaferri groundworks component speeds up construction of wards at Bradford hospital
ain contractor HACS retaining wall system comprising backfill to create a reinforced Construction put the dry-laid concrete blocks in earth structure of immense Mfinishing touches to a combination with Paragrid soil strength and durability. No mortar 4.5 m-high, 120 m-long MacWall reinforcement geogrids. or other wet trades are used. VSF segmental retaining wall. It Each course is located and The venture involved deep was built to create space for the connected using purpose-made rock-excavation within a £10 million fast-track, modular nylon/fibreglass pins that ensure severely constrained site. ward installation project at accurate alignment and setback Conditions meant that the Bradford Royal Infirmary. every time a block is placed. This wall had to be constructed as a The Maccaferri wall forms a makes installation simpler and combination structure of mass structural perimeter to the new quicker than for traditional wall concrete backfill along with building, allowing construction systems. traditional geogrid installation, of the wards to be at the same Geogrids are laid out behind to accommodate service ducts level as existing buildings on the wall face at 400-600 mm and existing features to the rear the site. vertical increments. These are of the wall. MacWall VSF is an engineered, sandwiched between the block The three-storey extension made reinforced segmental block, courses and layers of compacted space for an additional 56 beds.
www.britishprecast.org 23 lean and green precast product groups More than you see Precast cladding, flooring, structures and masonry are proving popular and even trading well through the economic downturn
n Architectural Cladding of bespoke precast concrete engineering detail must be Association cladding panels and detailed available and interfacing trades n the construction industry, design, delivery and fixing. So it are appointed concurrently. After the computer expression is important to understand the completion of the external design Iwysiwyg (what you see is what role a precast specialist plays in a and detailing, internal details are you get) can often be replaced by construction project. prepared. wygimtys (what you get is more While contractors and project Panels are erected on site by ACA than you see). managers concentrate on site member company teams trained Certainly, this is true of today’s activities, most of the precaster’s in safe handling and fixing, often architectural concrete cladding, work takes place off site. Hence without the need for an external where the surface attraction can the need for an adequate lead- scaffold. They are delivered to a hide a host of other qualities such time before work starts on site, tight programme, allowing large as built-in insulation, energy particularly when considering areas of the frame to be rapidly saving, structural performance, design and detailing. enclosed to give an early start recyclability and long life. The latter fall into two distinct to weather-sensitive following site ready to be used, having been As a result, even in the face phases: external or contract – trades. Window apertures within moulded in controlled factory of a construction downturn, it executed in conjunction with the panels can be framed, glazed conditions to virtually any form has maintained or perhaps even the architect, engineer and and sealed before delivery. or shape. grown its market share. interfacing trades; and internal There are also financial The high quality that results, Recent innovations in – as required for the production advantages inherent in combined with the unique production methods combined and installation of the precast architectural precast concrete. Off- chameleon property of being with significant investment units. site prefabrication and increased able to take on a multitude of in labour and plant resources In the external phase, the design on-site productivity, especially colours and surface textures, mean that architectural precast and drawings will include key using the largest practicable accounts for much of the surging concrete panels can be provided elevations, general arrangements units, give optimum value. interest in precast options. in an increasing range of finishes and builders’ work information, Similarly, with less dependence Concrete will continue to grow and facings, shapes and sizes. plans, sections and large-scale on site-based activities, in popularity and dominance. Each work package done by details. construction cost is stabilised Among the many reasons are: members of the Architectural If this element of design is to and construction time shortened, faster erection time, higher Cladding Association (ACA) proceed successfully, accurate so reducing costs. Of course, all quality, and the intrinsic lifetime typically includes the manufacture and complete architectural/ these advantages can be attained energy reductions from concrete’s only by early involvement of the thermal mass. specialist precaster. Techniques making use of Precast concrete cladding can precast concrete are being adopted be expected to last considerably for a whole range of projects. more that 60 years and generally This comes at a time when with no need for maintenance. Government statistics show that In addition, it is non-combustible the average density of new homes and fire-resistant with built-in has increased from 25 dwellings sound insulation properties per hectare to 40 in eight years. Dense concrete is also airtight Inevitably, this higher density and watertight, giving superior creates challenges such as noise weathering performance and transmission, and so concrete, corrosion resistance. Insulation which offers acoustic benefits, can readily be incorporated either is increasingly becoming the as a lining to the internal face of construction material of choice. a panel, or as a core between two concrete layers. Sustainability Moreover, the thermal mass At the same time, more and of concrete serves to reduce peak more emphasis is being heating and cooling loads. placed on sustainability and the environment. SPA members n Structural Precast On 11 June last year, the worked on the Association Government and the Strategic Ramada Hotel, recast concrete is the most Forum for Construction Barnsley versatile of construction published Strategy for Sustainable Pmaterials. It is delivered to Construction. This translates the 24 www.britishprecast.org Over 20 years, with a wider downturn, the precast Precast Flooring Federation is putting a lot of effort into concrete flooring promoting its benefits. has been steadily The vehicle for this programme is a series of technical seminars. “adopted as the The first of these, at Wembley material of choice” Stadium in October 2008 and Birmingham City FC in and pre-formed window panels, November, attracted considerable with solid concrete double- interest. Further seminars are spanning floor beams over two being planned, the likely venues rooms to aid speed of installation. being Newcastle, Manchester, The precast concrete wall panels Glasgow and Cardiff during late were designed as deep-beam spring and early summer, for walls to allow load transfer to details visit: www.precastfloors. the outer edges of the walls. info/cpdseminars. Each event will present a series n Precast Flooring of CPD-accredited technical Federation papers looking at the range of Bespoke concrete ith the introduction of issues affecting designers today. design at Barton some industry-wide tools, Several of the technical Square, Manchester Wgovernmental measures, papers present information on targets, and national standards innovatory products. Cobiax addressing sustainability, the flooring, developed by Hanson priority areas from the earlier Hope Hospital car park entire construction industry Building Products, is one of these. Securing the Future report Built for Salford Hospital Trust, is facing considerable pressure The system overcomes the into a series of targets and this SCC design-build project to take on the challenge of traditional issues associated with actions designed to enable the provides parking for 1,136 vehicles sustainable development. in-situ concrete construction, construction industry to meet on six levels on its Hope site. The precast flooring sector resulting in a more manageable, the challenge of making both Although the car park could realised the scale of this at a lighter structure, with less risk, its own operations, and the built be considered a basic design, very early stage and has been higher quality and a flat slab. environment, more sustainable. the client was keen to produce successful in addressing a Cobiaxdeck buildings have the It is clear that the industry a gateway building. This was number of means to tackle same structural integrity as full faces some tough challenges, achieved by the development different sustainability measures in-situ construction, but much of but how is precast concrete of an original concept design and implement a range of the work is removed to an off-site, positioned to play a key role in and by using grey ship-lapped product/process based solutions. factory controlled environment the improvements required? cladding on the service cores. Over the past 20 years, precast with just-in-time delivery to The precast concrete sector concrete flooring has steadily site. recognised long ago that many John Perryn Primary School been adopted as the material of When looking at the long- of the principles that underpin The two-storey £8.3 million choice, but with the construction term benefits, for example over sustainable consumption and John Perryn Primary School industry as a whole contending a 30-year period, the Cobiaxdeck production also make good in Ealing, west London, business sense and are, therefore, replaces a Victorian school. SPA members worked already embedded into many of Main contractor Willmott on the John Perryn the sector’s operations. Dixon opted for precast concrete Primary School in Member companies of the because of its fire resistance, west London Structural Precast Association flexibility, high quality, and (SPA) are approaching the market instant working platforms. in various ways. The common Buchan Concrete Solutions theme is to adopt modular developed the bespoke design. construction wherever possible, From the start, sustainability to increase speed and keep down was key. The most outstanding costs. feature being that 90 per cent A good example is precast of the demolished school crosswall construction. By building was recycled or design, the method provides used as piling mat material. flat soffits with no intruding downstand beams and also Ramada Hotel, Barnsley solves the increasingly onerous The 117-bed Ramada Hotel acoustic requirements of the in Barnsley was constructed Building Regulations. Typically, in just over 12 weeks, using programme gains over traditional Structherm’s Fastbuild precast and lightweight methods are 30– concrete system, with follow- 50 per cent. on trades able to start their Recent examples of work work as early as week nine. carried out by SPA members The building consists of include: directly decorated party walls www.britishprecast.org 25 approach arguably becomes the Hope for new homes if Government solution of choice. intentions are followed through Termodeck is another option. A building with an exposed concrete floor has a high thermal mass and is over a large surface area close to the occupants, so it can significantly influence the comfort levels for the users of the building. Passively, the concrete can absorb heat or radiate ‘coolth’ and will work to stabilise comfortable temperatures. The passive benefits of the high thermal mass properties of concrete can be significantly increased by the clever technique of passing the supply air through the thermal mass. The supply air passes through the holes in the hollowcore (which are primarily there to save concrete) at low velocities, allowing prolonged contact have pulled up stumps, providers have been forced to We need to between the air and the slabs. preferring the relative safety use imported timber frame kits In turn, this enables a far greater of refurbishing existing stock. at the expense of UK-produced work together area of concrete to behave as a With unemployment set to brick and block construction – as an industry to heat-exchange medium. rise steeply and the worldwide as a result of modern methods Behaviour in fire is also banking system still relatively of construction targets of 106 make sure we act highlighted. In two large-scale unstable, the outlook could be affordable housing projects. This “wisely and support fire tests on a hollowcore floor described as bleak for our hard is despite the fact that it added plate, supported on protected pressed industry. cost to the project and no doubt each other” steelwork, the plate performed Companies of all sizes are caused the loss of UK jobs. very well. The test results focused on survival, which means Now English Partnerships has completing up to slab stage and presented reinforce the real world cutting costs, improving agility scrapped these ill–considered then waiting until they have experience that hollowcore floor and managing cash flow, while targets, leaving housebuilders a confirmed buyer in place. slabs have good overall inherent looking for any opportunities. free to take advantage of a 15 per The housebuilder can then fire resistance. Some rays of hope are emerging cent cost saving with increased obtain bricks and blocks and n www.precastfloors.info/ based on the Government’s flexibility enabling them to build swiftly to affect an early cpdseminars intention to bring forward social support the local economy. handover of a completed home. housing projects and to insist For those in the private sector, Add to this the advantages of n Modern Masonry Alliance that the mortgage providers the challenges are immense, using a tried and tested product hese are unprecedented release funds in return for with falling land values and a that consumers want to buy and times for all those large Government injections of near stagnant market, cash flow you have the ingredients for Tinvolved in housebuilding, borrowed cash. is the key challenge. success in a buyer’s market. construction material production Faced with these challenges Masonry not only offers cost You will also be doing your and builders’ merchants. we need to work together as an savings when compared to bit to ensure we maintain The housebuilding sector industry to make sure we act timber frame, but it also provides the UK building materials is in near collapse and many wisely and support each other. complete flexibility. manufacturing industry, which social housing providers In the past, social housing Many housebuilders are is essential to our future.
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lean and green precast case study 3 3 /&'!&)$3&)!/-.,23&)3-.""+3!" '&)" Tens of thousands of jobs are being lost. Government to do, to ensure the return of Factories are being closed. People are liquidity and consumer confidence. losing their homes. Vital skills we need for the future are disappearing. The time has come for individuals and organisations to join the biggest ever It’s time to unite our fragmented industry to coalition of stakeholders in the built make our voice heard. We must articulate the environment and make our voice heard. most important things we need our It’s time for action to save our industry...
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