Spanwall Facades

This prominent office building overlooking the River Liffey – Fifteen George’s Quay was redeveloped by IPUT Real Estate.The headquarters office accommodation was expanded to over 70,000sqft with the addition of two new upper floors, a new landscaped roof garden and terraces, and a riverfront café. It now offers seven floors of high quality, highly sustainable headquarters office space in a prime riverside location.As part of the transformation, the entire façade was replaced and a bespoke metal rainscreen solution was developed and engineered by Spanwall in close collaboration with specialist façade contractor, Alucraft to deliver the architects’ contemporary vision and aesthetic for the building.The Cladding SolutionThe rainscreen façade design and specification had to provide long-term durability, weather performance, low maintenance and visual impact.The new envelope successfully blends stone, metalwork and floor-to-ceiling glazing with panoramic views.Spanwall’s rainscreen package for this prominent building involved the manufacture and assembly of over 6,000 components, and the CNC routing of over 10,000m of metal profiling.The aluminium cladding was polyester powder coated in two shades of bronze and was used to striking effect in vertical and horizontal rectilinear configurations which complement the stonework.Maximising Work Offsite to Facilitate InstallationThe construction methodology for the rainscreen system was to use offsite pre-assembly to maximise work in the controlled environment of Spanwall’s factory, before transporting pre-assembled multi-element panels to site for faster installation.The George’s Quay site had restricted access for deliveries and was highly constrained with very little space for material offloading and storage. This required a rethink of traditional cladding installation.By applying digital workflows and offsite processes to the project, Spanwall was able to fabricate 230 large, sub-assembled rainscreen panels, radically reducing the site installation phase for Alucraft.Meticulous Quality Control The cladding solution and use of offsite pre-assembly delivered meticulous quality control and a level of accuracy that can be very difficult to achieve on site. Each panel could then be installed seamlessly in the exact sequence – minimising material waste, storage, product damage on site, reducing vehicle movements, and maximising speed and construction efficiency.To address the restricted site access for deliveries, Spanwall and Alucraft used a just-in-time approach to achieve a highly efficient delivery and installation programme. This required stringent logistical planning, scheduling and collaboration at every stage.The Façade Contractor’s Perspective: Ronnie Mills, Managing Director of Alucraft:“The partnership with Spanwall on this project allowed close collaboration, in both design and manufacturing, and this proved hugely beneficial to the project. Being able to utilise the sheet metal production capabilities and knowledge from Spanwall’s team, with the expertise of our specialist façade team ensured that we had a streamlined the design-to-manufacturing workflow throughout the process.”“The bespoke rainscreen solution used Spanwall’s offsite manufacturing and assembly capabilities, ensuring that the sub-assembled rainscreen units could be delivered to site on a just-in-time basis. This allowed our site installation teams to better manage the logistical constraints of the site and fast track the façade installation. This reduced time and cost.”“We are delighted to have delivered another stunning façade, with the help of our long-standing supply chain partner, Spanwall.”

An Award-winning Facade ProjectThis project won the Best Use of Rainscreen Award at the Facade Awards in recognition of the outstanding design and delivery.Architects Sheppard Robson’s design for the external façade for this mixed use development included differentiating between the hotel and office sections by changing the building façade across its length. This resulted in the requirment for two separate solutions. The building features a striking sawtooth façade which uses KME TECU® Bronze and VMZINC Quartz-Zinc sheets formed into bespoke rainscreen panels from Spanwall. KME TECU® Bronze sheeting has a distinctive copper look and was used to clad the hotel element, with contrasting zinc cladding for the office development.  Design CriteriaThis was an extremely challenging design intent. Spanwall collaborated closely with Alufix Façades, the specialist sub-contractor, to create two innovative rainscreen solutions that could be manufactured and installed in the most efficient way possible. A bespoke hybrid rainscreen cladding system was manufactured by Spanwall, firstly fabricating rhomboid shingle panels into chevrons and then an aluminium rainscreen carrier panel.The chevron shingles were individually mechanically fixed to the carrier panel to produce a unitised facade solution.The copper and zinc finishes were chosen for their strong aesthetic appeal and durable and long-lasting properties. The TECU® Bronze finish is rarely used in a project of this scale and the warm, reddish hues will continue to age and weather, creating a unique finish for this significant building. Project Challenges The Farringdon Road project was developed on a constrained brownfield site in central London with restricted access. The size and fragility of the panels was a logistical challenges for the installation phase. Handling the unitised sub-assembled rainscreen units around the scaffolding, and installing it onto the finished façade, required stringent logistical planning and co-ordination between Alufix and Spanwall. The sizing of each unit was bespoke, and much larger than standard rainscreen units. Each unitised panel was manufactured in floor-to-floor heights up to 5m high and 2m wide. Spanwall manufactured and pre-assembled more than 10,000 parts into 150 zinc panels and 370 TECU® Bronze panels to reduce work on site. Throughout the process, tight manufacturing tolerances had to be adhered to. The rainscreen assemblies were extremely fragile and had to be packed and delivered to site avoding damage through the use of bespoke stillages for transport from the factory. The project also had an extremely demanding construction programme. Close collaboration between Alufix and Spanwall ensured the project was manufactured within the required timescale of just three months. Manufacturing excellence The rainscreen façade assemblies manufactured by Spanwall, were back ventilated with a system that enables the outer layer to breathe whilst the inner layer delivered the thermal insulation. The panels were manufactured in a quality controlled environment at Spanwall’s state-of-the-art factory in Belfast.Using advanced digital technology, its design team created a ground-breaking rainscreen solution that enabled the TECU® Bronze and small zinc shingle panels to be pre-assembled into larger rainscreen panel sub-assemblies, significantly reducing installation time to meet the programme requirements. Maximising work offsite in Spanwall's factory also minimised any impact of inclement weather during the installation phase. Customer FeedbackKarol Doherty, Technical Director, Alufix Façades:“The shape, scale and intricacy of the cladding types used on this project made this a complicated contract to delivery, which required a high-quality system to satisfy the exacting standards of the client and the architect. Having collaborated with the Spanwall team on other projects, and knowing their ability to deliver more complex and bespoke facade solutions on time and on budget, we had no reservations in bringing them on board as one of our key suppliers on the project.  There was a real collaborative and solution-focused effort to overcoming the challenges and complexities on this scheme and it was a pleasure working with Spanwall at each stage.” Image credit - VMZINC

Built to a budget of £100m, the iconic and multi-award winning Titanic Museum is the largest man-made tourist attraction in Northern Ireland and was a key part of the £7bn Titanic Quarter regeneration development. Spanwall's RF50 Rainscreen system was specified for this project and used for 4m panels set on the diagonal in an irregular configuration. This allowed the creation of geometrically complex shapes within the budget. 6,200 m2 of concealed fixed RF50 anodised panels were fabricated - punched or laser cut, routed and folded. The facade leans out at an angle of up to 18 degrees and 900 of the 2,000 panels were unique.The three-dimensional rainscreen panels were manufactured from almost 120 tonnes of 3mm J57S aluminium and appear two-tone in colour. In fact all the units were all anodised in natural silver and cover the four-pointed 28m high hulls of this maritime museum. This was a challenging project requiring around 2,000 different panels.Spanwall also worked on the interior where custom-rusted steel sheets were specified for internal walls and ceilings. The undulating system of steel plates has a patina in keeping with the site's ship-building heritage.A Multi Award-winning BuildingEuropean Aluminium Awards – Innovation Award and Overall Jury PrizeRICS Awards – Design and Innovation AwardBritish Construction Industry Awards – Major Building Project of the Year (over £50m) – FinalistRoyal Society of Ulster Architects Awards – Design Award

The Assembly Buildings in Hayes, London included the regeneration of the legendary Old Vinyl Factory - former home of EMI and where records for The Beatles and The Rolling Stones were pressed. This landmark site was redeveloped to create a mixed used scheme comprising new homes, offices, retail and leisure facilities.  Design criteria The project’s scope of works included the fabrication of new aluminium rainscreen cladding for three concrete-framed blocks of apartments.Spanwall worked closely with specialist subcontractor Eden Facades to develop a bespoke facade solution. The aluminium panels required concealed rear fixings to the support system. Spanwall’s RF50-FR rainscreen cladding solution was adapted to create a bespoke solution that met the design specification. The panels were polyester powder-coated for a durable finish. Project ChallengesThis was a large and complex scheme that had to be delivered to a short programme.  Project FeedbackMatt Green, Project Manager, Eden Facades:“Having spent over a decade building a reputation for quality and reliability, we know how important it is to work with suppliers like Spanwall who share our attention to detail and commitment to delivering excellence." “Spanwall consistently delivering innovative products and solutions with a quality service, and it was a pleasure to collaborate with their teams on this project.” 

Cladding of the newly constructed maternity unit at the Royal Victoria Hospital in Belfast used Spanwall’s RF50 metal rainscreen cladding system. This building is clad in a combination of 2mm Corten weathered steel and 1mm zinc.

A key design feature of the new station in Cambridge was to achieve a perforated design using the metal rainscreen cladding. The perforations within the cladding were intended to provide passive security and ventilation to the glazed areas around the concourse as well as views across the site. Spanwall worked closely with the contractor to engineer its RF50-FR rainscreen system for the project. The perforated aluminium cladding system was fabricated and finished in a polyester powder coated metallic silver. This units were installed in two sections and lifted into position during a short window through the night to minimise disruption to passengers and staff.

Spanwall RF50 Rainscreen system manufactured in three different panel depths and colours to achieve a staggered effect.Ireland's first Aloft Hotel - a Marriott International brand - is located in the heart of Dublin Liberties.The contemporary facade consists of glazing and aluminium rainscreen panels.The rainscreen system specified was Spanwall's RF50-FR - a 50mm deep fire rated and CWCT-tested hook-on cassette panel system. A contemporary palette of Du Pont grey and orange finishes were to create a striking urban facade.

One Elmwood is a £41.8 million student centre at Queen’s University Belfast. The four-storey, 11,000m2 hub was designed by studios Hawkins/Brown and RPP Architects and sits at the centre of the University’s campus. The building houses the student’s union, support services and non-faculty services. A unique space was also designed with the local community in mind. Visitors can benefit from office and co-working areas, event spaces as well as various lounges and bars situated around the building. Cladding DesignHawkins/Brown designed the façade to mirror adjacent buildings which include Whitla, The Lanyon and Elmwood Hall, bringing the old and new together. The complex design was required a bespoke solution. Using advanced digital technology, Spanwall created a sinusoidal system which is a corrugated profile in zinc. State-of-the-art manufacturing technology enabled Spanwall to manufacture the system with highly accurate circular perforations. The perforated cladding panels had an anodised finish, which gives the building envelope a more reflective surface. As the light hits the façade, this creates colour. Spanwall worked collaboratively with the design team to deliver the envelope system façade system in both form and function. BACK TO CASE STUDIES

This new bridge used Spanwall's RF50 in 3mm aluminum with a polyester powder coated finish in silver. The panels were configured as an asymmetrical curve along 120m.16,000 pedestrians and cyclists use the 120-metre Lagan Weir Footbridge each week. This is part of a more sustainable approach to travelling around the Belfast Waterfront area. The under-deck cladding was created using two Spanwall systems - the RF50-FR fire rated hook-on rainscreen and discreet-fixed SF40-FR fire rated panels. Part of the bridge required the RF50-FR panels to incorporate a curved aerofoil profile to displace and buffer the prevailing winds from the pedestrian deck. BIM technology was required facilitate the design and engineering process for two different radii at each edge and for the 1:20 curved elevation along the length of the bridge. Each panel was custom fabricated to fit in its precise location on the bridge deck. The cladding is fabricated from 3mm aluminium and was polyester powder coated in silver metallic to a marine grade finish because of the waterside location over the River Lagan.

The Paper Exchange is an 11-storey commercial building delivering Grade A office accommodation. Spanwall collaborated with facade contractor Clarke Facades to deliver the bespoke metal rainscreen panels that aligned with the architectural vision of Todd Architects.This was a complex design that was delivered with a combination of bespoke RF50-FR metal rainscreen panels to create a unitised solution. The panels were custom perforated meet the aesthetic and functional requirements. Spanwall also fabricated vertical fins, that had to precisely align in a vertical configuration for a seamless facade. The panels were fabricated in 2mm and 3mm aluminium sheets and polyester powder coated in a finish that has the appearance of weathered steel. This approach allowed the building to achieve a striking aesthetic and a robust finish.