IPP Ltd

Widely specified for its fire resistance and all round stability in the cladding build-up to apartment blocks as well as a render backer and sheathing board, IPP’s highly versatile Magply boards have been employed by a regional developer as a fireproof sarking board beneath taditional thatched roofing for a development in a beautiful Dorset village. The 12mm thick version of the high performance MgO material was selected by Poole based Charlew Developments, to comply with the project architect’s performance specification for the solitary thatched roof building on a nine house scheme in the village of Owermoigne, near Dorchester. Reflecting an aesthetic ethos similar to that adopted for Prince Charles’ landmark Poundbury development on the outskirts of Dorchester, local planners made the inclusion of a thatched property a stipulation of planning permission for the development and the exterior to the four bedroom dwelling also includes panels of flint-work between the bands of handmade brick which form the window surrounds. The thatch was installed by specialist roofing company, RV Miller from Keynes Wareham in Dorset. The overall roof construction saw the 12mm Magply boards being nailed down across the main rafters and covered by a breather membrane before battens were secured in the conventional manner, running across the pitches. The authentic reed thatch was then laid up the pitch and shaped around the eyebrow dormers at the roof edge and verges. “The project architects, Anders Roberts, specified the use of a one hour fire resisting board to be installed beneath the thatch covering. I researched a number of different board types before talking to our merchant, Travis Perkin, which recommended the Magply product. We have found the boards very straightforward to cut and fix before covering them with the breather membrane and battens.” Site agent for Charlew Developments, Jules Peach Backed by BDA Agrement certification, Magply MgO boards present a fire-safe and environmentally friendly alternative to conventional plywood or OSB products. The different thicknesses of panel are also widely used as a substrate board for flooring and flat or pitched roof build-ups as well as render systems.

Given the exposed location of the building the specification for the exterior cladding had to be both very durable and suitable for application in all but the most challenging of weather conditions. The solution decided on by the project team features a proprietary two-coat reinforced render system – K-Rend – spray applied to the Magply panels. “The original plans was to use a sand/cement render. However, after discussions regarding logistics and the scale of the elevations, it was decided to switch to a high performance render system and Fullers proposed the K-Rend on a substrate of Magply boards.”

Colchester based roofing contractor has been using Magply Recovery boards as part of a high specification build up, which provided operatives with a relatively quiet as well as safe means of carrying out re-roofing works to school classrooms during lesson times. Richard Tebbutt quoted ‘Because Magply is non-combustible, any excess bitumen can simply be burned off before the vapour barrier is installed as part of a Langley approved system’. As a high performance overlay board, Magply is manufactured from an MgO formulation. The board has been tested in the UK and carries Euroclass A1 Non-Combustible Fire Rating.

The Project Manager for White Haus, Tony Buck, commented: “We offer clients a bespoke service for the supply and installation of high performance timber frames to meet various specifications – right up to PassivHaus standard – building schools, hospitals and commercial premises as well as domestic properties. Although these structures aren’t within the designated five metre distance of existing buildings, the client (Emerson Properties) wanted the additional protection provided by a fire rated sheathing board – in addition to fire rated timber cladding – and we are using 9mm Magply boards on the outside of the timber frames. “

The MIB MetSIP is robustly engineered, with 75 mm deep cold-formed steel Sigma studs – plus a 45mm treated timber packer – at 600mm centres. 9mm thick Magply modified MgO boards form the inner and outer skins to the 136mm thick panels. Magply is largely unaffected by prolonged exposure to rain, while under independent testing, the material was shown to achieve 90 minutes fire resistance with minimal smoke generation. This means during the critical erection phase, before fire-stopping breaks and other permanent protection can be installed, the structure is far less vulnerable to arson or an accidental blaze.

The stylish three and four bedroom, two-storey properties present a traditional outward appearance, with clay roof tiles above the elevations of handmade bricks and highly weatherproof K-Rend panels. The latter is applied to the 12mm Magply modified MgO boards, screwed to 50x50mm timbers fixed at 600mm centres across the SIPS structure. Simon, the site foreman for Fullers Plastering, commented: “ This is the second time I have used Magply, Fullers having made the switch because it is an easier board to cut and fix, while it also takes the HP12 base coat very well.”

Recently completed 3,600m2 recovery board roof over the auditorium and sports hall uses perforated metal decking to span the main steelwork. Magply specified to carry 150mm of Hardrock DD underlay and a further 60mm of Hardrock Multifix insulation covered by a Sarnafil single ply roofing membrane. Stevie Jones, commented: “This is a large installation of some 3,600 square metres, with the auditorium and the higher level roof over the sports complex, both featuring the use of the Magply. They are being mechanically fixed to the decking prior to installing the two layers of Rockwool and then the Sarnafil membrane..”

Arena 1865 had to take several design criteria into consideration including provision of fire protection to safeguard the 4,500 spectators the steel framed structure can accommodate, while rigidity, all round durability and ease of installation were important. Simon Pugh-Jones outlined ‘We looked at a full range of board solutions including high performance gypsum and recycled plastic, but when we got into the science and the costings, it soon became clear the only board which ticked all the boxes was Magply’. Some 2000 m2 of the Magply 9mm boards were consumed in the main passageway beneath the Stand.

PassivHaus specialist Beattie is employing Magply as part of its high performance, site assembled system for a major affordable housing scheme currently under construction in Oxfordshire. Senior Project Manager Beattie, Benedict O’Halloran, comments: “We are now about to start work on some detached units which will be modular, but all of them use Magply boards for their racking strength, acoustic performance and fire resistance.“ Magply offers excellent racking strength, impact or pull-out resistance and all round ease of use in a variety of applications. Magply has been tested under BS EN 476 Part 22 for timber frame applications.

The five storey building is being clad across different elevations with either the Permarock exterior wall insulation system or the Dutch manufactured Brickworld brick slip system. Both are on Rockwool material fixed to an outside layer of 9mm Magply sheathing which also provides an additional 1 hour fire protection to the structure from the outside. : “Overall the Magply is easy to cut and fix, while as an MgO product it can get wet as many times as you want. That helps with programme timing while the price-point also makes it very affordable compared to other fire safe products'.

Externally the Magply boards are being covered with a vapour barrier and a 100 mm layer of high performance foam insulation. On top of this, at first floor level, a resin based render system is being applied, featuring a base coat, reinforcement mesh, and two more layers. Peter Spendley of ARG “We believe the Magply is transforming the feel of the new build system, offering additional structural strength and solidity, where occupants will be able to achieve a firm fixing anywhere they want internally. It also has a very good acoustic performance in terms or reducing sound transmission and reverberation.”

Graham Wakeman a Director of Wakes Construction Ltd., commented: “Old Street in Chatham is a prominent building, potentially exposed to severe weather where getting the exterior finishes right is critical. As the architects, Prime Folio identified the Baumit render system as the best for the situation, then through conversation with Baumit and the installer, it was a matter of matching it with a compatible substrate board: with Magply being chosen.” Despite offering good adhesion for the decorative render system, Magply boards are very moisture stable thanks to their modified MgO formulation that also represents an environmentally friendly alternative.

Oakworth design team recommends the use of Magply whenever the site survey and pre-contract assessment identifies a specific risk to adjacent properties in the event of a fire. The Magply boards also offer resistance to racking loads, both as part of the completed structure and during the installation process. Oakworth Production staff discovered that it not only cuts better, but the boards are not prone to cracking or splitting with the pressurised nail guns. It comes down to engineering and the design and we will always factor in the safety considerations, advising clients according on Magply as an option.