Construction Fixing Systems

Chelsea Waterfront is a transformative mixed-use redevelopment of the iconic Lots Road Power Station, originally built to power the London Underground. Designed by architecture firm Farrells, the project integrates low-rise townhouse-style buildings, the preserved power station, and two striking high-rise towers, all set amidst landscaped gardens open to the public.The façade design required a GRC band to be supported as well as masonry support, that sat directly above a GRC diamond. At the time, there was no company offering combined masonry and GRC support Brackets meaning that contractors usually need to deal with two suppliers and two technical teams, one for masonry support and one for GRC support. This naturally brings in the complexity of not only coordinating the two suppliers to ensure timely delivery but also coordinating the actual structural design.Having worked with CFS on a previous project, McMullen Facades approached CFS on behalf of the main contractor Midgard to see if there was some way to simplify the situation and invited CFS to tender.In theory, the GRC and masonry support brackets can be combined into one, however, it brings additional structural challenges to consider and requires a good understanding of structural engineering.Given CFS's experience both in the design of GRC support and masonry support, CFS were able to consider the additional design challenges and designed a novel type of combined masonry and GRC support bracket. The design adjustment resulted in savings on masonry support brackets due to smaller material use despite the brackets being relatively large.Using a combined bracket also meant that Midgard needed to work only with one supplier – simplifying the whole supply chain.Midgard rationalised the design to be modular and repetitive. This was achieved by using a small number of masonry pier variations and window openings allowing for repeated supports to be used throughout each level. All this meant that CFS were able to deliver just several variations of the combined GRC and masonry support bracket.Combined GRC and masonry support brackets bring a significant reduction in labour hours on site. Additional savings are made by simplification of the supply chain – this also reduces risk associated with supplier management and increases transparency across the project. This approach proved to be successful and is used in other projects to date.As a result, CFS now offers combined GRC and masonry support brackets to date.

Located along the Electric Boulevard, Battersea Power Station Phase 3a, designed by Foster + Partners, features the 164-room Art’otel, Battersea Roof Gardens, and Koa apartments, along with a variety of shops and restaurants. The project was developed by The Battersea Power Station Development Company, with Sir Robert McAlpine serving as the main contractor.Although technically considered a single building, Battersea Power Station is actually composed of several interconnected structures, each serving different purposes. The balconies, spanning levels five to thirteen, vary in design with some running along the entire building.However, due to the mixed-use nature of the development and subtle internal design modifications based on individual owner requirements, each level had unique load conditions with minimal repetition. Additionally, the project had to meet strict requirements for fire safety at REI 120 standard, as well as the need for additional thermal breaks for balconies.CFS designed all balcony connectors using the AVI Thermokorb system, a highly flexible solution that allowed us to create a custom design with 120mm insulation instead of the standard 80mm.CFS then assembled the balconies on-site in Medmenham, to allow for flexibility and to minimise any delays on site. With extensive experience in large-scale projects, we efficiently coordinated both the design and deliveries to ensure a smooth execution on-site.

Coventry Very Light Rail (CVLR) is a light tram / rail operating in Conventry.Designed to be one of its kind, the system is battery powered, eliminating the need for overhead wires. The low-profile track makes use of advanced materials to optimise its performance characteristics, whilst also employing standard rail parts where possible to ensure ease of manufacturing and use of existing supply chains.Although light rail systems offer benefits for cities in terms of transportation and air quality, the costs associated with system installation are often out of reach given funding constraints. Typical system costs may be in excess of £70 million per kilometre meaning that new networks are likely to run to billions of pounds. Early project research by the WMG-Coventry City Council team revealed that a significant proportion of these costs are related to the diversion of utilities. Convention light rail systems utilise deep foundations, leading to interaction with utilities and therefore resulting in diversions, delays and project management costs.Coventry City Council set WMG the challenge of developing a low-profile light rail track system that requires a dig depth of no more than 30 cm. A high-performance shallow slab system was developed meeting the requirements for mechanical performance due to both the light rail vehicles and heavy good vehicles. To achieve secure fixing of the rails to the high-performance slabs, the fixing inserts need to provide flexibility and be able to withstand the applied forces. Another consideration is for the fixing bolts to provide reliable integrity for long-term exposure. They have to be secure yet allow for enough movement caused by the tram cars and the material expansion due to the weather exposure. They also need to be durable to long-term repetitive loading from rail and road vehicles.The support from CFS helped WMG to deliver a functional design that has the potential to revolutionise city public transport infrastructure projects.CFS worked with WMG at the University of Warwick along with main contractor Galliford Try to deliver a functional design that has the potential to revolutionise city public transport infrastructure projects. Together with Ingerop and Rendel we are currently looking at changing the coating of the bolts to modify friction but provide equivalent corrosion protection as galvanising. The benefit is that the reduced friction can provide more reliable bolt torque to be achieved.Having worked together on this project WMG and CFS have started a partnership that focuses on new product development for the precast industry.

In March 2020, we were contacted by major UK-based contractor Midgard to review the masonry support designs at Fulham Riverside, a residential-led development on the North Bank of the Thames designed by architects Gillespies and developed by Barratt London.The team on site had noticed that the movement joint was being crushed and brought us on as consultants to carry out a full review of the design. Through our assessment, we found that the loads being experienced were significantly higher than had been allowed for, with loads in some areas as high as 35 kN, when as little as 11 kN had been allowed for.Despite being contacted initially as a consultant, we were brought on straightaway to restart the entire project. The existing masonry and support had to be stripped out and our own installed, and with the project falling significantly behind schedule as a result, everything – including the design work – had to be done at record pace, to help make up the time lost.Whereas most fully welded Masonry Support systems are rigid, ours was advantageous in that it is fully adjustable, covering all site tolerances by offering vertical adjustment, lateral adjustment and horizontal adjustment. As a result, we could work at speed and operate with enough flexibility to complete the project on time.

Designed by KKM Architects, Leyes Road will feature four new residential buildings, ranging from four to eight storeys, delivering 116 new carbon-neutral apartments as part of the Council’s ‘Affordable Homes for Newham’ programme. Notably, 40% of these will be dedicated to much-needed family homes, offering three- and four-bedroom units. The project is expected to complete in March 2026, with Bugler operating as both the main contractor and developer.The development in Newham aims connect the community and offer a strong identity and sense of place. The design uses high-quality materials, enhancing proportions to increase local interest. The project aims to mitigate environmental impact and whilst also addressing fuel poverty.CFS is proud to contribute to the development by supplying our Windposts to stabilise large wall panels and reinforce areas around openings. Manufactured from Austenitic Stainless Steel which provides excellent corrosion protection, CFS Windposts are designed to enhance structural integrity by reducing deflection and ensuring walls remain secure and straight. They also provide design flexibility for taller or longer walls without compromising structural safety, even in high wind areas.Photos taken from Bugler website.

Designed by Patel Taylor, the Lombard Wharf residential tower in Battersea boasts an eye-catching silhouette. The original design focuses on maximising the available provision of public space at the base of the building for pedestrian and cycle routes as well whilst preserving existing views of the river and the land. The projects distinctive twisting appearance was achieved with very subtle changes to the positioning of the white precast concrete balconies on each level.Upon completion in 2017 the project was awarded several prizes, including Housebuilder Awards 2016 and What House Awards 2017. Barratt London were both the main contractor and developer of Lombard Wharf. Our client Techrete was appointed to deliver the design and manufacture of the architectural precast concrete cladding for the façade. Despite the varying form, a high degree of repetition in the precast forms formwork costs. The formwork ‘masters’ changed for each set-back but were then repeated on each floor. Whilst the outer profile of the façade is always consistent, the inner profile varies through the use of a secondary former inserted into the main formwork shutter. The inner profile is lined with a thermal break connector (concrete-to-concrete) for connection to the reinforcement in the main structural slab. The balconies feature a waterproof membrane on the upper surface and are overlaid with a composite decking system.As the balconies form the perimeter of the building, they required a reliable supplier who would also be able to support with the balcony design. Having worked with the Construction Fixing Systems previously on various projects, including the V&A Museum in Dundee, Techrete approached CFS to provide a suitable solution for the thermal breaks.The Thermokorb® system by AVI proved the ideal choice as this is a very flexible thermal break system that allows wide range of concrete-to-concrete balcony designs. As a trusted partner, CFS has not only the capacity to supply large projects but also the expertise to support with the structural design of the thermal breaks. With assembly taking place at CFS’s Medmenham facility, CFS is able to deliver the system within 3 weeks from design to delivery to site for casting.

Ocean Drive project will deliver 373 homes including family and affordable housing across 4 apartment blocks to Leith in Edinburgh. Designed by architects 3Dreid with Hart Builders as the main contractor, the project will be one of Scotland’s most sustainable residential developments due to a 55% reduction in operational carbon emissions. Interestingly, all 4 blocks were built simultaneously.Initially, CFS were approached by subcontractors McAleer and Rushe with the plan to introduce masonry support on the piers at every other level up to the roof. This initially presented challenges, particularly at the corners, because of the large cantilever due to the shape of the building and the cavity depth.At Level 12, McAleer and Rushe had also intended to support all the way to the roof, spanning 2 and 3/4 levels. Unfortunately, this approach proved unfeasible due to excessive loads on the fixings, especially in the corners.To support the excessive loads on the fixings CFS recommended adding an additional support at Level 14 which relieved the load.Photo taken from McAleer and Rushe website.

Designed by architectural firm Kohn Pedersen Fox (KPF) and supplied by main contractor Canary Wharf Contractors, 1 Bank Street is a -framed office tower featuring a sloping western façade and flexible design based around cellular beams. The project was developed by The Canary Wharf Group. The 27 storey building was designed to achieve BREEAM ‘Outstanding’ rating, the highest level of certification a building can achieve for sustainability performance. The façade was designed to maximise the light coming in. However, due to its design, the loads that the panels need to withstand are significant.Due to our extensive expertise in the design and delivery of glass façade fixings, Construction Fixing Systems were approached by Lindner facades to discuss the design.CFS worked with Lindner facades to deliver a special design of cast-in channels for the façade, including the design and manufacturing of ski channels.

One Palace Street is a prestigious residential development in the heart of London, offering 72 private residences over 7 storeys above ground and 4 levels below with breath-taking views of Buckingham Palace gardens. Comprising of 6 buildings, 2 of which are grade II listed, One Palace Street is located to the south of Buckingham Palace within the Birdcage Walk Conservation Area.Led by Balfour Beatty as the main contractor and developed by Northacre and Palace Revive Development Ltd, the project combined specialist skill and craftsmanship to meticulously restore and enhance the unique island site. Architects Squire & Partners skilfully blended five architectural styles to create a seamless integration of heritage and contemporary living.CFS was proud to contribute to this iconic development by supplying Windposts to stabilise large wall panels and reinforce areas around openings. CFS Windposts enhance structural integrity by reducing deflection and ensuring walls remain secure and straight. They also provide design flexibility for taller or longer walls without compromising structural safety, even in high wind areas.Image taken from Northacre Developments website.

Regent’s Crescent is a historic site adjacent to Regent’s Park in London, designed by John Nash in the early 19th century. CFS worked with Main Contractor Midgard on the Regent’s Crescent project to provide a bespoke product for façade retention combining two cast-in channels and a bobbin. Designed by PDP Architects with AKT II providing structural engineering, the site was re-developed to comprise of sixty-eight new apartments and nine mews houses to the rear.Whilst the Grade I listed crescent façade is a standout feature of Regent’s Park, due to the damage from the War it was not viable to retain this. Following extensive research and consultation, Studio PDP decided to rebuild the Crescent, which is now the only Grade 1 listed façade to be rebuilt in the UK.There were many complexities and challenges to both the design and construction, including the fact that the site is surrounded on three sides by busy roads, including the Marylebone Road. A further challenge for this complex project involved considering the effects of vibration from the four London Underground lines that pass underneath the site.AKT II, the structural engineers working on the project, were looking at ways of mitigating the vibrations in a way that would be compliant with the conservation rules. This meant that they were unable to use traditional reveal angles.CFS have a long history of creating bespoke solutions, and as such we produced solutions to allow for both vertical and horizontal movement. This resulted in a bespoke product for façade retention combining two cast-in channels and a bobbin.

Back in 2020 we were contacted by McMullen Facades on behalf of main contractor Midgard to design and supply the Masonry Support for the Sackville Road project. Designed by Whittam Cox Architects, the former trading estate near Hove Station was transformed into an intergenerational neighbourhood featuring over 800 modern homes, including 564 Build to Rent units, 10% affordable housing, and 260 care community residences.The development provides long-term tenancy options and state-of-the-art amenities such as communal lounges, dining areas, shops, restaurants, and co-working spaces. With 70% of the site dedicated to public and green spaces, including roof terraces and landscaped gardens, the project aims to foster a vibrant and connected community.When designing Masonry Support for Block D of the project CFS encountered a hurdle of a Soffit which was unusually split into 3 sections – a front section, back section and a central GRC section.When designing Masonry Support for Block D of the project CFS encountered a hurdle of a Soffit which was unusually split into 3 sections – a front section, back section and a central GRC section.Whilst the front and back sections were easily supported with from the underside of our masonry support angle, this left the 550x2000mm GRC section completely unsupported. As a solution, we fixed 2 Brackets per panel to the underside of the downstand which meant that the central GRC section was now supported.We were delighted to contribute to the creation of a dynamic, intergenerational neighbourhood that prioritises community, sustainability, and modern living.

The Shard Quarter, developed in several phases, consists of three buildings: News Building, Shard Place, and Shard itself designed by Italian architect Renzo Piano. Thanks to Sheldebouw, a leader in the curtain wall industry, CFS were involved in the building of Shard and Shard Place.The Shard, designed by Renzo Piano Building Workshop, was designed as a ‘vertical city’. Shard Place (aka Fielden House) is a residential building built in the third phase of the development, with Mace as the main contractor.Sheldebouw were tasked with designing the building’s glazed envelope. The key challenge in the case of Shard was the building’s irregular shape. As the architect’s vision asked for a highly transparent facade with excellent energy efficiency, Sheldebouw opted for extra-clear low-iron glass. The glazing panels were installed to oversail the steel frames, making them invisible from the outside. Due to new regulations introduced in 2006, the whole façade was designed as a passive double-skin ventilated façade with built-in automatic fiberglass roller blinds.Similarly, Shard Place, built several years later, has a double-skin glass façade. In both cases, Sheldebouw needed an experienced partner to design and deliver fixings for the glass façade.CFS has extensive experience in designing fixing solutions for glass facades as well as project management to minimise any unexpected delays. Being able to combine our technical expertise and manufacturing capabilities this makes us an ideal partner for large complex projects.In both cases, CFS designed and delivered cast-in channels to fix mullions supporting the glass panels of the façade, including relevant T-bolts.

The Leadenhall Building, also known as the Cheesegrater, was designed by Rogers Stirk Harbour + Partners. Its distinctive angled façade sloping at 10.62 degrees was intentionally designed to preserve views of London landmarks such as St. Paul's Cathedral. Spanning over 224 meters high with 45 floors, the building features a ground-level public gallery, restaurants, office space and seven floors of plant rooms on the highest levels.This unique design features an unconventional structural system which sets it apart from other high-rise buildings in the city. The Leadenhall Building's structure comprises of two main elements: a superstructure on its perimeter comprising the office floors, alongside a northern support core, which houses all passenger and goods lifts, service risers, on-floor plant rooms and WCs. The office floors are then connected to the structural tube at every floor without the need for further perimeter columns.From design to construction, this was a challenging project to deliver as due to location the building’s substructure was divided into large components which were to be fabricated off site due to limited space. Space became even more limited as the levels increased, and during the project it was the first time that floors from the fifth level were assembled rather than poured on site.Construction Fixing Systems have an extensive experience for supplying components for precast concrete projects. For this project, we worked with main contractor Laing O’Rourke to supply Well Void as well and Continuity Rebar Couplers to connect the concrete slabs to the north core.

Victoria and Albert Museum of Design Dundee (V&A Dundee) is the first V&A built outside London. The design of the facade drew inspiration from the Scottish cliffs and the silhouette of the impressive facade imitates the shape of a ship at dock. Due to the complex geometric slopes and curvatures, coupled with its exposure to the Scottish weather and its proximity to the North Sea marine environment, architectural concrete was the favored material option for this project. The main contractor on the project was BAM Construction Ltd.To enable the vision of architects Kengo Kuma & Associates, Techrete designed bespoke fixings to attach the concrete facade to the main structure. They were looking for a manufacturer who could support them in delivering the solution, including about 18,000 cast-in channels.CFS worked closely with Techrete to manufacture the required precast facade support brackets in Duplex stainless steel. We have also worked closely during the building phase of this project to deliver the brackets in timely fashion.Since this project, CFS has supported Techrete on various projects and we keep working closely.

The Wembley Stadium project was one of the most expensive stadiums ever built, with costs totalling to over £789 million (£1.2 billion today).During the construction of the Stadium, Pyramid Builders provided the brickwork, blockwork, stonework, engineering, steel Windposts, firestopping and scaffolding along with the logistical management of all associated deliveries along with main contractor Multiplex Construction UK.The stadium was designed by Architects Foster and Partners with exceedingly high internal walls, and to make these walls stable, Windposts were required to increase lateral wall stability.CFS manufactured and supplied steel Windposts used in the construction. Manufactured from Austenitic Stainless Steel which provides excellent corrosion protection, CFS Windposts are designed to enhance structural integrity by reducing deflection and ensuring walls remain secure and straight. We also provide design flexibility for taller or longer walls without compromising structural safety, even in high wind areas.Based on the provided design, CFS provided custom manufactured steel Windposts up to 10m long to restrain the internal walls. These Windposts are integrated within the block walls.Image not by CFS.