Wetherby Wall Systems Ltd | Part of ROCKWOOL Group

Project OverviewLes Quennevais School is a major new-build education development delivering a state-of-the-art secondary school to meet growing demand and modern performance standards. The original 1960s school building had exceeded its design capacity and no longer met contemporary requirements for space, energy efficiency or learning environments.The new facility delivers approximately 60,000 m² of built area, incorporating a high-performance external envelope designed to provide long-term durability, fire safety and thermal efficiency, while achieving a distinctive architectural brick façade.Wetherby Wall Systems was appointed to provide a fully engineered external wall insulation (EWI) and brick slip system to meet the project’s technical, aesthetic and regulatory requirements.Design and Specification ObjectivesThe façade specification was developed to achieve the following:Provide a non-combustible, thermally efficient external envelope suitable for large-scale education buildings.Achieve targeted thermal performance in line with regulatory and client sustainability objectives.Deliver a genuine brick aesthetic to support the architectural design intent.Accommodate complex façade geometry, including multiple pillars, window reveals and detailed junctions.Ensure long-term durability, weather resistance and reduced maintenance requirements.Early collaboration between the design team, main contractor, installer and Wetherby Wall Systems’ technical team ensured the system selection and detailing supported both performance and constructability across a large and complex building footprint.System SpecificationThe specified façade solution comprised the following key elements:Substrate:Combination of traditional masonry blockwork and Steel Framing System (SFS).Insulation:Non-combustible stone wool insulation boards, selected for their fire performance, acoustic properties, moisture resistance and long-term compressive strength.Thermal Performance:Variable insulation thicknesses were utilised across the building to achieve a design U-value of ≤ 0.30 W/m²K, supporting energy efficiency and occupant comfort.Façade System:Wetherby Brick Slip System, incorporating:Real fired clay brick slips, manufactured using traditional brick production processes.Matching corner units (“pistols”) to ensure consistent detailing at returns, reveals and façade junctions.Reinforced base coat and mechanical fixing strategy to support long-term system integrity.Finish:White smooth clay brick slips, delivering a contemporary architectural appearance with the visual authenticity of traditional masonry.All components were supplied as part of a fully compatible, system-based solution, designed to maintain performance continuity across the building envelope.Installation and Technical DeliveryGiven the scale of the project, installation required detailed coordination and phased delivery across multiple elevations.Key technical considerations included:Mechanical fixing of stone wool insulation to both blockwork and SFS substrates.Integration of reinforced base coats and system build-up to support the extensive brick slip finish.Careful detailing at complex architectural features, including columns, window reveals and interface zones.Ongoing technical support and site inspections provided by Wetherby Wall Systems’ site support managers to ensure compliance with specification guidance and installation best practice.The use of a brick slip system significantly reduced programme duration and installation complexity when compared to traditional full brick construction, while maintaining the desired architectural finish.Performance OutcomesAchievement of targeted thermal performance, supporting reduced operational energy demand.Non-combustible façade solution suitable for large-scale education environments.Durable, weather-resistant external envelope designed for long-term performance.Delivery of a genuine brick aesthetic across one of the largest brick slip façades in Jersey, utilising over 500,000 clay brick slips.Architect and Specifier ValueThis project demonstrates how a system-based stone wool EWI and brick slip façade solution can be successfully applied to large, high-profile education developments. It highlights the benefits of:Non-combustible insulation for fire safety and acoustic performance.System compatibility across mixed substrates (masonry and SFS).Efficient construction methodology without compromising architectural intent.Early technical engagement to resolve complex detailing and performance requirements.Client and Stakeholder FeedbackSarah Hague, Headteacher, Les Quennevais School, commented:“The new Les Quennevais School will truly be a school for the future. It will inspire and drive the ambition of a whole new generation and transform the experiences of our staff and students. We are hugely excited, proud and feel truly privileged to at last have the facilities that match the outstanding teaching that we deliver day in, day out.”Project SignificanceAs one of the largest brick slip façade installations in Jersey, this project represents a benchmark for the use of non-combustible EWI systems in large-scale education buildings, combining performance-driven specification with high-quality architectural outcomes.

Project OverviewAudley Cooper’s Hill is a high-profile heritage refurbishment and residential conversion project located within Magna Carta Park, Englefield Green, Surrey. The scheme involves the transformation of the former Brunel University Runnymede campus — a Victorian Gothic building of historic significance — into a luxury retirement village for residents aged 55 and over.The 67-acre site is being redeveloped to provide 128 residential properties, alongside shared amenities including a health club, swimming pool, restaurant and library. The project required a façade solution capable of improving thermal performance while preserving the architectural character and visual integrity of the historic building.Wetherby Wall Systems was appointed to provide a technically robust external wall insulation (EWI) system that would balance modern performance standards with heritage sensitivity.Design and Specification ObjectivesThe façade specification was developed to achieve the following:Improve thermal performance in line with current regulatory and sustainability objectives.Provide a non-combustible, impact-resistant insulation solution suitable for long-term residential operation.Maintain architectural fidelity to the original Victorian Gothic design.Deliver a high-quality, consistent rendered finish across complex elevations.Ensure long-term durability and reduced maintenance for a managed retirement village environment.Early coordination between Audley Group, Balfour Beatty and Wetherby Wall Systems’ technical team ensured system selection and detailing supported both performance requirements and heritage considerations.System SpecificationThe installed façade solution comprised the following system build-up:Substrate: Existing masonry construction.Insulation: 90 mm non-combustible stone wool insulation boards, selected for their consistent density, high compressive strength and excellent impact resistance, making them well-suited for use behind thin-coat render systems.Thermal and Fire Performance: Stone wool insulation provides improved thermal efficiency while delivering robust non-combustible fire performance, supporting regulatory compliance for residential applications.Reinforcement and Base Coat: Reinforced base coat incorporating alkali-resistant mesh to enhance system integrity and façade resilience.Finish: Wetherby Thin Coat Render System with 1.5 mm silicone render, in white, delivering a consistent, high-quality architectural finish with excellent weather resistance and vapour permeability.All components were specified as part of a fully compatible, system-based solution to ensure continuity of performance and long-term façade durability.Installation and Technical DeliveryThe project required careful technical coordination due to the building’s historic fabric and complex architectural detailing.Key technical considerations included:Integration of the EWI system with existing masonry substrates.Detailing at ornate architectural features to maintain visual continuity.Consistent application of thin-coat render to achieve uniform colour and texture across varied elevations.Ongoing technical support provided by Wetherby Wall Systems to ensure compliance with specification guidance and installation best practice.Performance OutcomesImproved thermal efficiency of the building envelope.Non-combustible, impact-resistant insulation solution appropriate for long-term residential use.Durable, vapour-permeable façade finish designed for weather resistance and reduced maintenance.High-quality architectural outcome that respects the historic character of the original structure.Architect and Specifier ValueThis project demonstrates how a thin-coat, stone wool EWI system can be successfully applied to heritage refurbishment and high-end residential developments. It highlights the importance of:System compatibility with historic masonry substrates.Impact resistance and compressive strength for long-term operational buildings.Balancing performance compliance with architectural sensitivity.Early technical collaboration between system provider, contractor and developer.Client CommentaryKevin Shaw, Managing Director, Audley Group, commented:“The retirement village model is very different to that of traditional housebuilders. We continue to operate and manage our villages long after construction, so it is essential that we work with partners who understand the importance of long-term quality and performance.Audley Cooper’s Hill will be an enviable retirement village in a prime location, and this development represents a natural next step in our successful partnership with Balfour Beatty.”Project SignificanceAudley Cooper’s Hill represents a benchmark for the application of modern, non-combustible EWI systems within heritage-led residential developments. The project demonstrates how contemporary performance standards can be achieved without compromising the architectural identity of historically significant buildings.

Project OverviewBelmar Court and Asbury Court are two prominent high-rise residential towers in Linwood, each comprising 16 storeys and 87 flats, originally constructed in the 1970s. The electrically heated buildings had poor thermal performance, contributing to high energy costs and fuel poverty among residents.As part of Linstone Housing’s wider regeneration programme to align its housing stock with Scottish Housing Standards, the towers were identified as priority assets for a comprehensive building fabric upgrade. The project adopted a “fabric-first” approach, focusing on improving the thermal and performance characteristics of the external envelope through a high-performance external wall insulation (EWI) system.Design and Specification ObjectivesThe façade specification was developed to:Deliver a substantial improvement in thermal performance to reduce operational energy demand and resident heating costs.Provide a non-combustible, fire-safe EWI solution appropriate for high-rise residential applications.Ensure compliance with relevant wind load, structural and building regulation requirements.Transform the external appearance of the towers with a durable and visually distinctive façade.Early technical engagement between Wetherby Wall Systems, E.ON Energy Installation Services Ltd and the project structural engineers ensured the system design was robust, compliant and suitable for the building height and exposure conditions.System SpecificationThe installed EWI solution incorporated the following elements:Substrate: Existing cavity wall construction, with remedial works and installation of replacement cavity wall ties prior to system installation.Insulation: 100 mm non-combustible stone wool insulation boards, selected for their high fire performance, thermal efficiency and acoustic properties.Fixing Strategy: Mechanically fixed system, with fixing type and density determined through wind load calculations and mechanical pull-out testing to ensure suitability for 40-metre-high elevations.Reinforcement and Base Coat: Reinforced base coat incorporating alkali-resistant mesh, providing impact resistance and long-term system integrity.Finishes:Dry dash finish (cream) to all elevations, delivering a hardwearing and durable surface.Wetherby Silicone ‘K’ 1.5 mm render panels (terracotta) used to create visual contrast and architectural definition across the façade.All components were specified as part of a fully compatible, system-based solution designed to maintain performance continuity and regulatory compliance.Thermal PerformanceThe completed system delivered a significant improvement in building fabric performance:Pre-refurbishment U-value: 1.41 W/m²KPost-refurbishment U-value: 0.29 W/m²KThis level of improvement supports compliance with current building regulations and delivers meaningful reductions in heating demand for residents.Installation and Technical DeliveryGiven the height and age of the structures, the project required a high level of technical coordination and quality control.Key delivery elements included:Structural assessment and remedial works to address existing cavity wall ties.Wind load analysis and on-site mechanical pull-out testing to validate fixing design.Ongoing technical support and specification guidance provided by Wetherby Wall Systems’ technical team throughout installation.Coordination between installer, funding partner and structural engineers to ensure regulatory and safety compliance.Performance OutcomesMajor improvement in thermal efficiency across both towers.Non-combustible façade solution suitable for high-rise residential use.Durable, low-maintenance external finish appropriate for exposed elevations.Enhanced visual identity of two landmark residential buildings.Reduced fuel costs and improved comfort for residents.Architect and Specifier ValueThis project demonstrates the application of a non-combustible, stone wool EWI system on high-rise residential buildings. It highlights the importance of:Early structural and wind load assessment.Fixing validation through mechanical testing.System compatibility and façade durability in exposed, high-rise conditions.Technical collaboration across client, engineer and system provider.Stakeholder FeedbackA spokesperson for E.ON Energy Installation Services Ltd commented:“This was an important refurbishment project for Linstone Housing and it was vital that the EWI not only significantly improved energy efficiency, but also transformed the appearance of the flats.Wetherby’s technical team played a crucial role in ensuring the most appropriate system was installed, advising on fixings, detailing and remedial work to ensure correct installation and long-term performance. This project represents best practice in the planning and delivery of high-rise external wall insulation.”Project SignificanceBelmar Court and Asbury Court serve as a benchmark for the delivery of high-rise, non-combustible EWI systems within social housing refurbishment programmes, demonstrating how performance-driven specification can address fuel poverty, regulatory compliance and long-term asset improvement.

Project overviewLovell Park Towers form part of a major residential estate in Leeds that underwent a large-scale energy efficiency and fire safety upgrade. The project included three 17-storey tower blocks—Lovell Park Grange, Lovell Park Heights and Lovell Park Towers—and was delivered as part of a £25 million refurbishment programme led by Leeds City Council in partnership with Equans.The primary objective was to significantly improve thermal performance, reduce carbon emissions and provide a fully non-combustible façade solution suitable for high-rise residential buildings.The challengeThe refurbishment programme presented several complex challenges:Delivery of works to multiple high-rise blocks simultaneouslyRequirement for a fully A1-rated non-combustible external wall systemMixed substrates, including brickwork and in-situ concrete panelsConstrained site logistics with limited storage and compound spaceA need to achieve substantial improvements in energy efficiency without altering the building formIn addition, the system design had to account for wind loading, fixing performance and consistent detailing across all elevations.The solutionA Wetherby direct fix A1 external wall insulation system was specified across all three tower blocks. The system incorporates non-combustible ROCKWOOL stone wool insulation and mineral-based components throughout, achieving an A1 fire classification.The insulation was mechanically fixed directly to the existing brickwork substrate on the majority of elevations, with thinner insulation specified for reveals and recessed areas to maintain façade alignment and detailing continuity.Wetherby carried out wind load calculations and pull-out testing during the design phase to determine the appropriate fixing specification and layout for the varying substrates and building heights.InstallationThe EWI system was installed by Hamilton Building Contractors Ltd, a Wetherby-recognised contractor and INCA member. Installation was carefully coordinated with the main contractor to ensure continuity of works across all three towers.In areas where concrete panels were present beneath window openings, a double-layer insulation approach was adopted. An initial layer of insulation was fixed to the concrete substrate, followed by a secondary layer aligned with the main façade insulation, creating a consistent external plane prior to rendering.Finishes and detailingThe façade was completed using a mineral render system finished with silicone paint, providing a durable, weather-resistant finish suitable for high-rise exposure conditions.A combination of colour tones was used to articulate the façades, with lighter colours applied to primary elevations and darker accent colours used in recessed areas to visually unify the three towers. Brick slip finishes were incorporated at ground level to provide enhanced impact resistance in high-traffic areas.The resultThe refurbishment delivered a substantial improvement in thermal performance, with external wall U-values reduced from approximately 1.41 W/(m²K) to 0.28 W/(m²K).The completed works provide a fully non-combustible façade solution, improved thermal comfort for residents and a significant reduction in operational energy demand. The project demonstrates how high-rise social housing can be effectively upgraded to meet modern fire safety and energy efficiency standards.Key factsSystem: Direct fix A1 external wall insulationSubstrate: Brickwork and concrete panelsInsulation: Non-combustible stone woolFinish: Mineral render with silicone paintFire performance: A1-rated systemU-value improvement: From ~1.41 to 0.28 W/(m²K)

Project overviewThe Limes is a large-scale mixed-use development comprising refurbished and new-build residential accommodation alongside a specialist care facility. The project was delivered as a landmark regeneration scheme, combining modern construction methods with a strong architectural identity informed by the site’s historical context.The development was designed and constructed using lightweight steel framing and required an external wall solution capable of delivering high levels of fire performance, thermal efficiency and architectural flexibility.The challengeThe scale and complexity of the development presented a number of technical challenges:Use of lightweight steel frame construction across a large multi-storey buildingA requirement for a drained cavity solution compliant with new-build warranty requirementsHigh fire performance standards suitable for multi-occupancy residential useA façade design incorporating multiple materials, colours and finishesExtensive façade detailing, including recessed openings, parapets and balconiesThe façade system also needed to achieve very low U-values while maintaining durability and impact resistance.The solutionA Wetherby cavity rail external wall insulation system was specified for the steel frame construction. The system incorporates a partially ventilated drainage cavity between the sheathing board and insulation, providing effective moisture management while maintaining strong thermal performance.Non-combustible ROCKWOOL stone wool insulation was installed within the system, delivering both high thermal efficiency and an A1 fire classification in accordance with BS EN 13501-1.The system was finished using a combination of real clay brick slips and silicone thin-coat render, allowing the façade to replicate traditional masonry while achieving the performance benefits of a modern lightweight construction.InstallationThe façade system was installed by Fox Contracts under the coordination of the main contractor. The use of Wetherby RagRails simplified installation while allowing precise control over cavity depth and façade alignment.Due to the complexity of the building geometry, bespoke detailing was developed for areas such as splayed embrasures and parapet junctions. In locations where brick slips were not suitable, a render finish was specified to maintain both performance and visual clarity.Close coordination between the façade contractor, system designer and roofing contractor ensured robust junction detailing and continuity of insulation across the entire building envelope.Finishes and detailingBrick slip finishes were used extensively across the façades to provide a robust, impact-resistant surface with the appearance of traditional masonry. Multiple brick colours were specified to articulate the building mass and reflect the architect’s design intent.Rendered areas were finished using Wetherby Silicone 4S Render, selected for its durability, water resistance and suitability for installation across varying weather conditions. Four different render colours were used to define architectural zones and create visual rhythm across the elevations.The resultThe completed façade system delivered exceptional thermal performance, with external wall U-values ranging from approximately 0.10 to 0.16 W/(m²K), significantly exceeding typical regulatory requirements.The project demonstrates how cavity rail external wall insulation systems can be successfully applied to large-scale steel frame developments, delivering high fire performance, excellent thermal efficiency and architectural flexibility.Key factsSystem: Cavity rail external wall insulationSubstrate: Lightweight steel frameInsulation: Non-combustible stone woolFinish: Brick slips and silicone renderFire performance: A1-rated systemU-values achieved: Approximately 0.10–0.16 W/(m²K)

Project OverviewHill Quays is a prominent mixed-use development in central Manchester comprising 266 residential apartments, ground-floor commercial units and basement parking, arranged across two interconnected buildings — Block A and Block B — linked by elevated walkways and spanning approximately 3,500 m² of façade area.Block B, which accommodates 42 high-specification residential units, was identified as the primary focus for a comprehensive façade remediation programme. The project was among the first in the region to secure support from the Building Safety Fund (BSF), established to address life-safety fire risks associated with external wall systems on buildings over 18 metres in height.Wetherby Wall Systems was appointed to design and supply a fully engineered external wall insulation (EWI) solution that would enhance fire performance, durability and regulatory compliance while maintaining the building’s architectural character and thermal efficiency.Design and Specification ObjectivesThe façade specification was developed to:Replace the existing system with a like-for-like A2-rated, non-combustible external wall system.Improve fire performance and life safety compliance in line with BSF and Building Regulations requirements.Maintain or improve thermal efficiency without altering the building line or architectural intent.Provide a robust, versatile façade solution capable of accommodating complex geometry and mixed substrates.Ensure long-term durability and weather resistance for a high-rise urban environment.Although the original performance requirement targeted a U-value of 0.28 W/m²K, the completed system exceeded expectations, achieving a final performance of 0.24 W/m²K.System SpecificationThe installed Wetherby system comprised the following build-up:Substrate: Mixed construction including Steel Framing System (SFS) and traditional masonry.Sheathing Board: WeatherKem Calcium Fibre Cement Board (A1 non-combustible), introduced as a replacement sheathing layer where original system data was unavailable. This provided a compliant, stable and fire-safe backing for the EWI system.Insulation: ROCKWOOL stone wool insulation, selected for its A2-s1,d0 fire classification in accordance with BS EN 13501-1, along with excellent thermal, acoustic and durability characteristics.Insulation Thicknesses: Variable thicknesses of 30 mm, 40 mm, 50 mm, 60 mm and 90 mm were specified to accommodate façade articulation, columns and complex interface zones while maintaining consistent thermal performance across elevations.Fixing Strategy: Direct mechanical fixing into studs and masonry substrates, with pre-installation pull-out testing ensuring minimum fixing performance of ≥1.0 kN. Fixing type and density were tailored to substrate condition and insulation thickness.Reinforcement and Base Coat: K+A reinforced basecoat, incorporating alkali-resistant mesh for impact resistance and long-term system stability.Finish: Wetherby 4S Silicone Render (Four Seasons Render), selected for its extended application window (1°C to 30°C and up to 95% relative humidity), providing flexibility in programme delivery and a durable, weather-resistant façade finish.Thermal PerformancePre-refurbishment U-value: 0.28 W/m²KPost-refurbishment U-value: 0.24 W/m²KThe system delivered improved thermal performance while meeting enhanced fire and durability requirements for a high-rise residential environment.Installation and Technical DeliveryThe project presented several technical challenges, including:Mixed substrates comprising SFS and masonry.Slender façade elements, projecting columns and confined interface zones.Management of multiple insulation thicknesses across complex elevations.Key delivery measures included:Extensive testing and validation of existing façade elements.Development of a revised specification incorporating A1-rated sheathing.On-site coordination between Wetherby Wall Systems, Springforward Management Ltd and Cobe Contracting Limited.Ongoing technical support and quality assurance to ensure compliance with specification guidance and regulatory standards.Performance OutcomesEnhanced fire performance and life safety compliance through a non-combustible, A2-rated façade system.Improved thermal efficiency exceeding initial design targets.Durable, weather-resistant façade suitable for high-rise urban exposure.Successful remediation delivered under Building Safety Fund requirements.Architect and Specifier ValueThis project demonstrates the application of a direct-fix stone wool EWI system for high-rise remediation and fire safety compliance. It highlights the importance of:Early testing and validation of existing façade systems.Integration of A1-rated sheathing boards within remediation strategies.Variable insulation specification to address complex architectural geometry.Collaboration between system provider, installer and main contractor to meet regulatory and funding requirements.Project SignificanceHill Quays serves as a benchmark for Building Safety Fund–supported façade remediation, illustrating how performance-led specification and system-based design can deliver enhanced fire safety, durability and energy efficiency within complex, mixed-use high-rise developments.

Project overviewCwrt Andrew Bychan is a three-storey retirement housing development owned by Wales & West Housing. As part of the Welsh Government’s Arbed energy efficiency programme, the building underwent a façade retrofit to improve fire safety, thermal performance and weather resistance while enhancing the external appearance.The project was delivered with residents in occupation, requiring careful sequencing and a solution that balanced performance, compliance and minimal disruption.The challengeThe key requirements for the project included:Improving thermal performance to meet modern energy efficiency standardsSpecifying a fire-safe façade solution suitable for multi-storey residential useIntroducing visual interest without compromising durability or complianceAchieving consistent detailing around openings, projections and roof junctionsMaintaining a high standard of workmanship in an occupied buildingThe client also sought a façade finish that combined a clean, contemporary appearance with textured detailing in feature areas.The solutionA Wetherby masonry stone wool external wall insulation system was specified for its non-combustible insulation, thermal performance and design flexibility. The system incorporated A1-rated ROCKWOOL stone wool insulation boards and was finished using a combination of silicone render and acrylic brick slip finishes.The primary finish was Wetherby Silicone 4S Render, selected for its rapid curing properties, high water repellence and resistance to variable weather conditions. Acrylic brick slips were introduced as a contrasting feature, providing the appearance of traditional masonry in a lightweight, flexible format.The complete system achieved an A2-s1, d0 fire classification in accordance with BS EN 13501-1, making it suitable for buildings of any height.InstallationThe system was installed by SMK Building and Maintenance Ltd, a Wetherby-recognised contractor. Installation followed Wetherby’s approved detailing guidance, including:Interlocking insulation boards at all junctionsL-shaped insulation boards at opening corners to minimise cracking riskInsulated plinth detailing at damp proof course levelFully detailed pitched and flat roof junctions to prevent water ingressWetherby provided ongoing technical site support throughout the installation to ensure compliance with system requirements and detailing standards.Finishes and detailingIn addition to the primary render and brick slip finishes, feature areas such as porches and window surrounds were enhanced using a quartz mosaic render. This bespoke finish introduced additional texture and visual interest while remaining fully compatible with the overall façade system.The combination of finishes allowed the building to achieve a refreshed, contemporary appearance without losing its original character.The resultThe retrofit delivered a significant improvement in thermal performance, with the external wall U-value reduced from approximately 1.27 W/(m²K) to 0.24 W/(m²K).The completed façade provides enhanced fire safety, improved weather resistance and long-term durability, delivering a safer, warmer and more energy-efficient environment for residents.Key factsSystem: Masonry stone wool external wall insulationSubstrate: MasonryInsulation: 120mm non-combustible stone woolFinish: Silicone render, acrylic brick slips and quartz mosaic renderFire performance: A2-s1, d0U-value improvement: From ~1.27 to 0.24 W/(m²K)

Project overviewCharrington Court is a high-rise residential building that underwent a comprehensive façade remediation programme to address fire safety concerns and bring the external envelope in line with current regulatory expectations. The project was initiated following inspection findings that identified discrepancies between the as-built façade materials and the original design intent.The remediation works focused on replacing combustible elements with a fully compliant non-combustible façade system while maintaining the building’s existing appearance and thermal performance.The challengeThe project presented a number of technical and operational challenges:Replacement of combustible façade materials on an occupied high-rise buildingA requirement to retain the existing architectural appearance and colour paletteMultiple substrate types, including steel frame and masonry constructionUneven existing substrates requiring façade levellingRestricted site footprint limiting storage and material handlingThe need for extensive resident engagement throughout the worksIn addition, the client required the remediated façade to achieve an A2-rated system while maintaining a target U-value of 0.18 W/(m²K).The solutionA Wetherby cavity rail external wall insulation system was specified to meet the fire, thermal and aesthetic requirements of the project. The system incorporated a drained cavity between the insulation and the substrate, providing enhanced moisture management and suitability for high-rise construction.The façade build-up included non-combustible ROCKWOOL stone wool insulation fixed to Wetherby Ragrails, creating a cavity zone before the application of the decorative finishes. This configuration allowed the system to accommodate substrate irregularities while delivering consistent thermal performance and fire resilience.Both brick slip and silicone render finishes were used to replicate the original façade appearance, ensuring continuity with the surrounding urban context.InstallationThe EWI system was installed by MK Facades, a Wetherby-recognised contractor with extensive experience in complex remediation projects. United Living acted as main contractor, coordinating the multi-disciplinary works.Prior to installation, Wetherby carried out pull-out testing across multiple elevations and heights to verify fixing performance. Wind load calculations were also undertaken to determine the appropriate fixing specification and spacing, ensuring compliance with project-specific structural requirements.In areas where the existing substrate was uneven, a double-boarding approach was adopted to level the façade before the application of the finishing layers.Finishes and detailingThe primary render finish was a silicone thin-coat system with integrated anti-crack properties and UV-resistant pigments, enhancing long-term durability and colour stability. Alkali-resistant reinforcing mesh was incorporated into the basecoat to provide additional strength in high-stress areas.The combination of rendered and brick slip finishes allowed the system to closely match the original façade design while upgrading its fire and thermal performance.The resultThe completed remediation works delivered a fully non-combustible external wall system with an achieved U-value of 0.18 W/(m²K), meeting both the client’s thermal targets and current fire safety expectations.The cavity rail system provides long-term moisture management, improved durability and enhanced fire performance, ensuring the building’s façade is compliant, resilient and fit for continued residential use.Key factsSystem: Cavity rail external wall insulation systemSubstrates: Steel frame and masonryInsulation: Non-combustible stone woolFinish: Silicone render and brick slipsFire performance: A2-rated systemAchieved U-value: 0.18 W/(m²K)

Project overviewWood Lane Court and St Mary’s Court are two residential blocks owned by 54 North Homes that underwent a major retrofit programme to improve energy efficiency, fire performance and long-term durability. The project formed part of a wider decarbonisation strategy, targeting reduced heat loss, improved occupant comfort and compliance with current retrofit standards.The works were delivered in partnership with Equans and included external wall insulation (EWI), upgraded heating systems and improved ventilation across 98 occupied homes.The challengeThe project presented several technical challenges typical of occupied retrofit schemes:Mixed construction types, including masonry and timber frame substratesMultiple balconies, passageways and recessed areas requiring careful detailingExisting asbestos-containing roof coverings at Wood Lane Court, limiting roofline alterationsThe requirement to deliver PAS-compliant retrofit detailing without disturbing the existing roof structureA need to significantly improve thermal performance while maintaining safe, robust façade junctionsThe solutionA Wetherby stone wool external wall insulation solution was specified to address both thermal and fire performance requirements. The system was installed to a mix of masonry and timber frame substrates and incorporated non-combustible ROCKWOOL stone wool insulation, achieving an A2 fire rating.At Wood Lane Court, one of the key technical innovations was the use of Wetherby’s PAS-approved roofline closure system on the gable elevations. Rather than extending the façade up to the asbestos roof, the system was carefully dropped below roof level and detailed using a brick slip soldier course to maintain weather protection and continuity of insulation without disturbing the roof covering.The roofline detail followed Wetherby Detail A4, incorporating a grind-in profile suitable for limited existing roof overhangs. This approach ensured effective protection against rainwater ingress and thermal bridging while maintaining compliance with retrofit standards.InstallationThe EWI works were carried out by Thomas Niamh Contracting Ltd, a Wetherby-recognised contractor and INCA member. The system build-up comprised:12mm sheathing board100mm non-combustible stone wool insulation mechanically fixed to the substrateReinforced basecoat and thin-coat silicone render finishAt St Mary’s Court, additional timber framing and sheathing boards were installed within passageways to accommodate the insulation system and ensure continuity of performance around complex junctions, including doorways and balconies.Finishes and detailingBoth buildings were finished using Wetherby HECK 4S Silicone ‘K’ 1.5mm textured render. Multiple colour tones were used to articulate the façades, with darker colours at ground level and lighter finishes to upper elevations to improve visual balance and reflectivity.Careful attention was given to detailing around balconies, walkways and recessed elevations to ensure durability, weather resistance and long-term performance in high-exposure areas.The resultThe completed works delivered a substantial uplift in thermal performance, with external wall U-values improved from approximately 1.41 W/(m²K) to 0.28 W/(m²K). The upgrade is expected to significantly reduce energy demand, lower carbon emissions and improve internal comfort for residents.The integrated roofline closure system provides long-term protection against water ingress and thermal bridging, enhancing the overall effectiveness and lifespan of the EWI installation.Key factsSystem: Stone wool external wall insulation with PAS-compliant roofline closureSubstrates: Masonry and timber frameInsulation: 100mm non-combustible stone woolFinish: Silicone thin-coat renderFire performance: A2-rated systemU-value improvement: From ~1.41 to 0.28 W/(m²K)

Project OverviewGeoffrey Woolley House is a high-rise residential refurbishment project located at 5 Pollard Street, London E2 6LY. The scheme forms part of a wider building fabric upgrade programme focused on improving fire performance, durability and thermal continuity across the external envelope.Wetherby Wall Systems was appointed to design and supply a non-combustible, system-based external wall insulation (EWI) and façade solution, supported by structured technical oversight and post-installation quality assurance. Installation was delivered by MK Facades under the main contract with United Living.Design and Specification ObjectivesThe façade specification was developed to:Provide a non-combustible external wall system suitable for high-rise residential application.Ensure regulatory compliance with current fire safety and building control frameworks.Deliver a durable, weather-resistant façade with long-term performance assurance.Integrate system compatibility across mixed substrates, including steel frame and masonry construction.Achieve consistent architectural finish across complex elevations and interface zones.Early technical engagement between Wetherby Wall Systems, United Living and MK Facades ensured the system build-up, fixing strategy and detailing were aligned with both regulatory and constructability requirements.System SpecificationThe installed façade system comprised the following system build-up:SubstratesSteel Framing System (SFS) sheathed with cement particle board (12 mm Y-Wall)Masonry and concrete constructionSheathing / Carrier Layer12 mm cement particle board, providing a non-combustible, stable and durable backing for the EWI system where SFS was present.InsulationNon-combustible stone wool insulation, selected for its fire performance, vapour permeability, acoustic benefits and thermal efficiency.System Build-Ups180 mm stone wool insulation with 14 mm brick slip façade system (approximately 732 m²)140 mm stone wool insulation with HECK 4S silicone render system (approximately 161 m²)Fixing StrategyDirect mechanical fixing into steel frame studs and masonry substrates.Fixing density and layout validated through mechanical pull-out testing, confirming minimum performance thresholds prior to system installation.Reinforcement and Base CoatReinforced basecoat incorporating alkali-resistant mesh to ensure impact resistance and long-term system stability.Finish SystemsBrick slip façade finish, delivering a traditional masonry appearance within a lightweight, system-based build-up.HECK 4S silicone render, providing a vapour-permeable, weather-resistant and durable rendered façade finish.Thermal and Fire PerformanceThe system specification prioritised:Non-combustible insulation performance, suitable for high-rise residential application.Thermal continuity across mixed substrates and interface zones, supporting improved building fabric performance.Vapour permeability and moisture management through the use of breathable insulation and silicone-based finishes.System performance data, fixing validation and detailing guidance were issued in line with Wetherby Wall Systems’ technical specification and installation requirements.Installation and Technical DeliveryInstallation was carried out by MK Facades, a Wetherby recognised and carded installer, under ongoing technical oversight.Key quality assurance measures included:On-site inspection by Wetherby Technical Support Manager, confirming system compliance across substrates, fixings, reinforcement layers and finish application.Verification of fixing strategy, corner detailing and opening perimeters, including stainless steel fixings and maximum 300 mm centres at critical zones.Review of reinforcing mesh overlaps, stress patches and basecoat thickness to ensure impact resistance and system continuity.Confirmation that ventilation openings remained free from obstruction.Validation that all previous inspection actions had been resolved.The final site inspection confirmed 100% project completion and full compliance with Wetherby’s system specification, with no remedial works required. MR-1950 Site Report - Geoffrey The project is covered by a 10-year Wetherby system guarantee, issued following:Confirmation of full system complianceSubmission of proof of purchase and installation recordsVerification of trained, carded operatives on siteCompletion of mechanical pull-out testing and final inspection sign-off Wetherby Wall Systems GuaranteePerformance OutcomesDelivery of a non-combustible, high-rise appropriate façade system.Integration of brick slip and silicone render finishes within a single, compatible EWI framework.Verified installation quality through structured technical inspection and sign-off.Long-term assurance supported by a 10-year system guarantee.Enhanced durability, weather resistance and architectural consistency across all elevations.Architect and Specifier ValueThis project demonstrates the application of a stone wool-based, system-led EWI solution on a high-rise residential refurbishment scheme. It highlights the importance of:Early validation of fixing strategies through mechanical testing.System compatibility across steel frame, concrete and masonry substrates.Integration of brick slip and rendered finishes within a unified technical specification.Structured quality assurance and third-party-style inspection processes to support compliance and guarantee issuance.Project SignificanceGeoffrey Woolley House serves as a reference scheme for the specification of non-combustible, stone wool EWI systems on high-rise residential buildings. The project demonstrates how performance-driven façade design, technical oversight and system-based specification can deliver compliant, durable and architecturally refined refurbishment outcomes supported by long-term assurance.

Project overviewRoyal View is a high-rise residential building located in the centre of Brighton that underwent a major façade remediation programme as part of the UK Government’s Cladding Safety Scheme. The project focused on replacing the existing external envelope with a fully compliant, non-combustible façade solution that met current fire safety and performance requirements.The works were delivered through a collaborative supply chain, with a strong emphasis on regulatory compliance, durability and long-term performance.The challengeThe remediation project required a technically robust solution capable of addressing multiple constraints:Replacement of combustible façade materials on an occupied high-rise buildingCompliance with current fire safety legislation and Building Safety Act requirementsMixed substrates, including steel frame and masonry constructionRestricted site access and limited storage due to the building’s city-centre locationThe need to improve thermal performance without altering the building’s formThe façade system also needed to provide long-term weather protection and low maintenance performance in a coastal environment.The solutionA bespoke Wetherby external wall insulation solution was specified, combining systems suitable for both masonry and steel frame substrates. The façade incorporated non-combustible ROCKWOOL stone wool insulation throughout, delivering an A1 fire-rated solution suitable for high-rise residential use.The insulation boards were mechanically fixed to the substrate and finished with Wetherby silicone render, providing a water-repellent yet vapour-permeable external finish. This combination delivers robust weather resistance while allowing moisture vapour to escape from the building fabric.The system is certified by BBA and KIWA and is fully compliant with current fire and performance standards for high-rise residential buildings.InstallationInstallation of the façade system was carried out by APEX Facades Ltd, a Wetherby-recognised contractor, under the coordination of the main contractor. The works were carefully sequenced to minimise disruption to residents and to manage access constraints typical of dense urban sites.Strong coordination across the project team ensured that façade works, cladding interfaces and associated components were integrated effectively, maintaining programme control and quality assurance throughout the installation.Finishes and detailingThe façade was finished using Wetherby silicone render, selected for its durability, colour stability and resistance to weathering. The finish provides a uniform appearance across the building while delivering long-term protection against moisture ingress and environmental exposure.Careful detailing was implemented at junctions and interfaces to ensure continuity of fire performance and weather resistance across the full building envelope.The resultThe completed remediation works delivered a fully non-combustible external wall system with significantly improved thermal performance. External wall U-values were reduced from approximately 1.30 W/(m²K) to 0.28 W/(m²K).The upgraded façade provides enhanced fire safety, improved energy efficiency and a durable, low-maintenance external envelope suitable for long-term residential use.Key factsSystem: Masonry and steel frame external wall insulationSubstrates: Masonry and steel frameInsulation: Non-combustible stone woolFinish: Silicone renderFire performance: A1-rated systemU-value improvement: From ~1.30 to 0.28 W/(m²K)