"sfs"

A requirement in Corstorphine Wright’s design brief was to avoid horizontal movement joints in the finished façade, which would have been the result had a traditional SFS Infill to concrete frame approach been taken. Working with Willmott Dixon at the early design stages of the contract, Metsec’s in-house design team proposed a continuous walling solution formed from SFS to support glazing and rendered elements that would form the external skin of the façade. Metsec’s solution included the use of fixing cleats to connect the SFS continuous walling to the structure’s concrete frame.

Fresh Wharf is being developed by Countryside, in partnership with housing association Notting Hill Genesis on a 10-acre, former brownfield site situated along the banks of the River Roding. Demolition of old premises on the site started in early 2018 and Phase 1 of the construction project commenced later that year. After this, construction of the new properties commenced in earnest, with the apartment blocks and townhouses being constructed. Installation was undertaken by sub-contractor, Stanmore, with Metsec using Revit to create the construction level design for the framing system at the early stages of the project’s conceptualisation.

This major redevelopment of Charlton Park Academy school involved replacing temporary mobile classrooms and a single storey building with a two-storey steel framed brick building to better meet the needs of students, teachers and carers. A structural flooring solution was required for use over precast planks, covering 800m2 on the ground and upper floor at a depth of 75mm to 120mm. Space and access would be challenging, due to the small footprint of the site, proximity to the existing school building and access from a busy main road. Given the large floor area, a traditional sand cement screed would have been very time consuming to place. Tarmac’s TOPFLOW SF a self compacting steel fibre reinforced concrete was chosen as the solution. Its flowing nature would allow it to be quickly pumped into place and adapt to the variable thickness criteria. TOPFLOW SF is designed to act as a structural topping with both, steel mesh & fibre reinforcement. The steel fibres added to the TOPFLOW SF gave its robustness and flexural strength as it was being placed over a precast plank system that could flex with loadings. They also reduced the risk of cracking. By replacing steel mesh reinforcement, it helped avoid problems with access, storage and handling and kept the site open for parallel trades. Using TOPFLOW SF rather than a sand cement screed or reinforced concrete, improved productivity and saved time. This saved 13 days or just over 2.5 weeks on the programme. 

The University of Salford’s new Science, Engineering and Environmental (SEE) building features a white RainScreen façade, punctuated by contrasting red window reveals with a sloping sill to form recessed windows. While this creates an impactful design statement, it proved challenging when it came to evaluating the RainScreen insulation performance.The thermal performance challengeFrom the outset the designers, in conjunction with the University, outlined a desire for non-combustible insulation. But the feature red reveal details meant there were restricted cavity widths near the windows, which would affect the depth of insulation that could be installed. Several Mineral Wool insulation manufacturers had been unwilling to undertake U-value calculations. This was because it was challenging to understand the weighted U-value across the different façade build-ups and determine the U-value uplift required to compensate for the shallower window reveal areas.Architects Sheppard Robson had previously worked with Knauf Insulation and engaged its Project Specification Team to discuss the challenge and develop calculations.After receiving the plans, Knauf Insulation undertook 3D U-value calculations and confirmed that they could meet the required thermal performance – and crucially it would mean no changes to the design or impact on the cavity widths.Accurate 3D U-value calculationsSo how could Knauf Insulation meet the brief when other manufacturers could not?The crucial factor was the type of U-value calculation used. Most manufacturers use the standard method, which calculates the U-value for the build-up without the metal substructure. Because this method doesn’t consider the effect of the metal penetration through the insulation, a blanket correction factor is added, which can lead to the under- or over-specification of insulation. Either way, it means that the insulation used in the finished project may not deliver the thermal performance that has been specified. And in the case of the SEE building, calculating the weighted U-value to prevent this was critical.Knauf Insulation uses numerical modelling (also known as 3D U-value calculations) as standard for all RainScreen façade projects. This methodology thermally models the build-up taking into account the complex interaction between the insulation and the bars and brackets of the steel framing system (SFS). As a result, it creates the most accurate available picture of how the build-up will perform thermally after construction.For the SEE building, the team undertook several different calculations changing elements of the build-up, including the substructure material and insulation widths, until they determined the optimal combination.High performance insulationBy using this rigorous calculation method, Knauf Insulation was able to meet the brief with a combination of 50mm and 160mm Rocksilk® RainScreen Slab, along with 200mm OmniFit® Slab 35.Rocksilk® RainScreen Slab is a Rock Mineral Wool slab that is BBA certified for use at any height and for the broadest range of thicknesses and build-ups on the market. It has a thermal conductivity of 0.034 W/mK.OmniFit® Slab 35, a Glass Mineral Wool slab with a thermal conductivity of 0.035 W/mK, is ideal for use in the SFS.Both Rocksilk® RainScreen Slab and OmniFit® Slab 35 are non-combustible with the best possible Euroclass A1 reaction to fire classification so they will not contribute to the development or spread of fire should it occur. Thanks to their sound absorption characteristics, critical for low mass rainscreen structures, they will help create a quieter environment for the computer and science labs.A sustainable solutionThere was one other specification factor to consider – sustainability. The SEE building had been designed to minimise its environmental impact in line with the University of Salford’s campus master plan.Matthew Taylor, the project architect from Sheppard Robson, noted: “From early on, sustainability has been high on the SEE building agenda, including becoming one of the first all-electric University educational building.” The building will also be supported by photovoltaic panels on the roof.But while the use of renewable energy sources and high performance insulation will help lower the building’s operational carbon, it was important to keep embodied carbon to a minimum.Here Glass Mineral Wool scores highly too because it has the lowest embodied carbon of any mainstream insulation material.Knauf Insulation has proactively reduced the embodied carbon in its products over the years, as part of a broader set of activities to reduce its environmental impact. Specific actions to minimise its carbon footprint include initiatives to reduce road miles in both sourcing and distribution.For example, its Glass Mineral Wool products are manufactured using up to 80% recycled content, including glass collected from the local communities around its factories. The finished products are then compressed by up to 10:1 to fit more product into each lorry reducing transport related carbon emissions.Another innovation is ECOSE® Technology, its unique bio-based binder contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly.Products made with ECOSE® Technology are also soft to touch and easy to handle. They generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.Ongoing supportThe through-wall build-up was installed by Metclad Contracts. As this was the first time they had worked with Rocksilk® RainScreen Slab, they also turned to the Specification Team for installation advice. They wanted to know whether the insulation should be fixed into the sheathing boards or the SFS.Knauf Insulation provided details of the fixing pattern together with the installation guide. They also facilitated meetings with their fixing partner to provide specialist technical support about pull out values and requirements for fixing into the substrate.Thanks to Knauf Insulation’s extensive technical expertise and ongoing support, the vision for the University of Salford’s state-of-the-art SEE building has become a reality – without any compromise on thermal performance, fire safety, acoustic or sustainability.

Installer – Metclad ContractsMain Contractor – R G Carter, CambridgeArchitect – MCW ArchitectsClient – University of BedfordshireSystem(s) – Vantage®️ SF in Anodised Regency Gold and PPC 9006 Syntha Pulvin Bespoke Curved Internal Rooflights and bespoke flashings throughout.The University of Bedfordshire has invested 40 million pounds in this new STEM building at its Central Luton campus.STEM stands for Science, Technology, Engineering and Mathematics (STEM) subjects, however Pharmaceutical and Chemical Science, Nutrition, Biochemistry, and Mechanical Engineering are also taught there.The project was a very big challenge to our design teams as the specification from MCW architects was predominately regency gold anodised . This spec calls for a special grade of aluminium and the finish means that we must leave welds as laid. Consequently, we had to consider different methods of fabrication to resolve with stunning resultsWe supplied our Vantage®️ SF Hook on rainscreen in both regency gold and powder coated, 9006 Silver however, the pinnacle of our supply was the bespoke curved anodised rooflight in silver 9006

Installer – County RoofingMain Contractor – Barnwood ConstructionArchitect – Scott BrownriggClient – Centre for Agriculture and Bioscience InternationalSystem – Vantage® SF (Secret Fix)Showcasing our premium CWCT tested Vantage® SF (Secret Fix) in 3mm aluminium powder coated to Ral 7016 anthraciteThe project received many accolades and awardsCABI HQ shortlisted for AJ Architecture AwardConstructing Excellence SECBE 2021 Awards - WinnerOxPropFest 2021 - WinnerUK Roofing Awards 2021 - FinalistArchDaily Building of the Year 2021 - NominatedSECBE People's Choice Award 2021 - NominatedFuture Cities Forum Awards - Highly CommendedAJ Architecture Awards - ShortlistedWe feel very humbled to be associated with such a fantastic project and a big well done to all involved

The Vantage EMF project was pioneered over a year ago in the boardroom of our partner, The Expanded Metal Company in nearby Hartlepool. Managing Director, Phil Astley discussed the principle and BTS Facades & Fabrications put it into practice.We both deemed the idea as that unique that we engaged an intellectual property firm who achieved the patent pending statusThe system utilises the tried and tested Vantage SF technology. The frame is fabricated and the expanded mesh is cut to size on our Streibig Saw. The mesh showcased here is the Athens although, it also available in Bilbao and Madrid.Vantage® EMF systems were tested earlier this year at the VINCI Technology Centre UK. The mesh is fitted to the frame and then powder coated both sides.The bespoke vantage SF rail with pre positioned hooks and anti rattle gasket is fitted to the wall and then the Vantage EMF panels are hooked into placeOur Vantage CS coping competes the scene here to stunning visual effect. We inserted LED lights in the perimeter of the frames to automatically light up at dusk to compound the effect.

In 2012 the town of Walsall underwent a major regeneration. The Waterfront North site was developed and was based on 2.2 acres of brownfield land, where more than 300 homes and apartments, as well as a Premier Inn hotel were to be constructed. RCM were appointed by Whitbread to provide Y-wall, an advanced flexible calcium, silicate based fibre cement building board, for the construction of the Premier Inn. This was to be used as an external sheathing board, covering the structural steel frame, infilled with SFS steel.

Project: Broxbourne Business CentreDate: 2022 Background:·        APL were engaged with the architect early in the project design and specification process·        APL worked closely with the architect and powder-coating manufacturers to select the correct colour shade for the perforated areas·        APL’s design team assisted with detailing the challenging interfaces between different cladding types·        APL provided all structural calculations Systems:·        550m² of APL SnapLoc™ traditional standing seam system in steel with a RAL 7016 PUF coating ·        700m² of APL AP18HR-Airwall™ perforated sinusoidal profile with an APL Oxide3 PPC coating ·        APL Tritherm™ GALV sub-framing to SFS substructure for APL SnapLoc™ areas·        APL AluE™ Tritherm aluminium sub-framing for AP18HR-Airwall™ areas·        All flashings, fixings and accessories  Building Location:·        Broxbourne

Project: The Renaissance Date: 2022 Background:·        APL’s strong supply-chain relationships enabled the correct specification of aluminium and paint coating for a marine environment to be secured at a time of severe material shortages·        APL’s design team worked closely with the installer, helping to detail the challenging interfaces between different cladding types·        APL provided all structural calculations Systems:·        1,000m² of APL SnapLoc™ traditional standing seam system on marine-grade aluminium with a PvF2 coating in RAL 9002 and RAL 9006·        APL Tritherm™ GALV sub-framing to SFS and concrete substructure for APL SnapLoc™ areas·        100m² of APL Custom Bespoke Newton-range castellated profile in aluminium·        PPC aluminium infill panels and copings·        Complex bespoke feature flashings in PPC aluminium ·        All flashings, fixings and accessories  Building Location:·        Hove

Project: Greenlaw Business CentreDate: 2018 Background:·        APL were involved from an early stage with the architects, providing design and costing advice throughout the tendering process·        APL’s strong supplier relationships ensured that long-lead items were all delivered to the project timeframes·        APL’s design expertise enabled a bespoke profile to be created to meet the architects vision and inhouse fabrication capability upto 6m in length resulted in single-length profiles and flashings Systems:·        1,000m² of Newton-range custom bespoke in aluminium with an anodised-bronze coating·        850m² of AP6ZS factory-produced standing-seam built-up system·        APL Tritherm™ GALV support system onto SFS·        LB4 live louvre system·        All flashings, fixings and accessories  Building Location:·        Glasgow

Project: Middlebeck SchoolDate: 2021 Background:·        APL was specified by the architect, being engaged early in the design process·        The architects vision required numerous bespoke samples to be made, with an ultra-clean secret-fix version ultimately being chosen ·        APL’s strong production processes ensured all materials were delivered to site on time Systems:·        950m² of APL custom bespoke secret-fix castellated profile in aluminium with a PPC coating ·        APL Tritherm™ GALV subframe to support panel system onto SFS·        All flashings, fixings and accessories  Building Location:·        Newark 

Exterior Accoya cladding has been selected by the University of Minnesota for The Tashijan Bee Pollination Centre. Designed by Architects MSR, 8,000 square feet of Accoya Burn and Brushed Black, coated in Delta Millworks ebony SF, features on the siding of the building and was chosen due to its durability and sustainable properties. Plus, in keeping with the ecological mission of the build, Accoya was the perfect fit due to its green credentials – thereby; the building meets the National B3 Sustainability standards as well as State of Minnesota Sustainable Building 2030 requirements.

We were delighted to collaborate with Prater on the Bracknell regeneration project. The Marks and Spencer building was one of 6 blocks that we were involved in cladding. This building showcases BTS Fabrications’ Vantage SF Rainscreen in three shades blue, and white high gloss Alucobond. The combination of cladding and timber creates a stunning effect.

It’s the ‘Desert Mist’ powder coated finish that makes this project specialIt’s a stunning two tone Adapta finish from their Patina range and is available with a warrantyThe system is our CWCT tested Vantage r SF (Secret Fix) RainscreenThis new state of the art health centre was jointly funded by NHS England and Milton Keynes Council and we are proud to have been involved

Installer – Richardson RoofingMain Contractor – John F Hunt LtdArchitect – Scott BrownriggClient – Firmdale Hotels plcSystem(s) – Vantage®️ SF and bespoke flashingsThis is our premium CWCT tested secret fix rainscreen located in this trendy part of London.The rainscreen is 3mm aluminium and powder coated to RAL 7016 and RAL 7037.It is showcased on all 4 elevations of this residential and office development directly adjacent to the Soho hotel.It was an interesting challenge for our logistics team delivering to this urban development with very limited access and plant.BTS Facades & Fabrications smaller sprinter vehicles were used for handball unload on site.BTS are proud to be involved with yet another Scott Brownrigg architectural design.

Project: Leeds College of BuildingDate: 2018 Background:·        APL were involved from an early stage with the architects, providing design and costing advice throughout the tendering process, along with significant design support as the project progressed·        APL’s technical expertise and close relationships with its supply chain ensured that solutions were provided to some very complex colour requirements Systems:·        1,400m² of half-round profile AP50HR in aluminium with an anodised-look PPC finish ·        850m² of sinusoidal profile AP18HR in aluminium with an anodised-look PPC finish ·        APL Tritherm™ GALV support system onto SFS·        LB4 live louvre system·        All fixings and accessories  Building Location:·        Leeds

Our client worked on a new development that included five, seven and nine-storey apartment blocks situated on Academy Street in Warrington. We were pleased to supply our Cortex® 0500FR Class B Membrane. The Cortex® FR Sealing System was applied around windows and the SFS.

As a consequence of the Grenfell tragedy, an assessment of the building envelope was carried out on the 275nr residential apartment block in the centre of Leeds. It was found to be non-compliant with current regulations and in urgent need of replacement.The VariAL-SF system was selected as it complied with an A2 fire rating, with EN13501-1 classification by third parties, and satisfied the detailed planning constraints.The importance of the cladding refurbishment and replacement on this high-rise residential building cannot be understated. The building was identified by West Yorkshire Fire & Rescue Service late in 2019 as being high risk from the perspective of residents safety, due to the fact it was clad in flammable panels and onus was placed on the building owner to take swift action to make the building safe. As such, an ambitious 52 week programme for complete removal of the existing cladding and replacement was set out and achieved by the project team, despite significant limitations in terms of access and logistical challenges.To the passer-by, there is barely any discernible difference in the aesthetic of the building’s new facade, the colour-matching of the panels is incredibly accurate and allowed for a seamless transition to a much safer environment for the building’s residents.The apartment block was in the middle of a built up residential area. The contractor needed to obtain road closures from Leeds city council for two main roads which ran the full length and one side elevation.Furthermore the other main elevation was a pedestrian walkway with access to the apartment block , a hotel and several commercial buildings therefore safe access routes and segregation had to be installed and coordinated with the various parties involved.In addition, the building had to be reclad using 125ft cherry pickers working off the main road and pedestrian walkways therefore protective tracking systems had to be laid over the tarmac and paving to protect the existing materials.Throughout the building refurbishment, which took exactly 52 weeks, access to all the various buildings was maintained and contractor site personnel worked closely with adjacent building owners and especially the management team of the apartment block which accommodated 270 apartments to ensure minimal disruption.

Project DescriptionThe Forbury Place development began in 2014 as the largest speculative office development in the UK outside of London, and is now considered to be Reading’s newest urban business district. The estate offers 600,000sqft of prime office space across 3 office buildings in the heart of Reading’s city centre. No1 Forbury Place is home to global company SSE, and has deservedly been recognised for architectural excellence thanks to its distinctive exterior façade.Specific Project ChallengesProject specific design and application of a floor to floor spanning rainscreen support system.Bespoke designed and fabricated 3D peel effect aluminium panels.Continuity of façade finish, from rainscreen panels across to brise-soleil and curtain walling systems.Solutions OfferedThe specification and engineering of the S150 VariAL H box mullion allowed floor to floor spanning, fixed at slab levels, to prevent point loading of the rainscreen system back to the SFS.Trial panels were manufactured in-house prior to supply on site to ensure architectural intent was interpreted accurately.Powder coating procurement through a single source applicator for all elements of the façade, to guarantee colour continuity.

The campus in Colchester, which is home to 15,000 students, is undergoing a massive phased transformation. Benx-RCM are currently supplying into phase three of the campus-build, known as The Pastures.Split across five new buildings, The Pastures will bring an additional 1,262 student bedrooms to the Colchester campus. One of these blocks will create a new hub which will include a reception, a post room, an administrative area and a student services centre, along with a laundrette and staff welfare facilities.Overseeing this £168 million project as main contactor is Bouygues Construction.Stanta were awarded the SFS infill package at the site. As part of this package, Benx RCM were selected to supply Y-Wall external sheathing board for the entire project.Y-Wall is a flexible calcium silicate based fibre cement building board, offering excellent fire properties as well as high levels of dimensional stability. The Y-Wall BBA Certification provided the Stanta project team with assurance that this building board solution has been tested to exacting standards, evaluated onsite, as well as undergoing a life expectancy assessment and a quality management system review.Y-Wall was utilised to create a sheathing for the five high rise structures. In buildings with storeys more than 18m above ground level, any products used in the external wall construction should be of limited combustibility. Being a non-combustible, A1 fire-rated building board, utilising BS EN ISO 1182 and BS EN ISO 1716 tests, Y-Wall is the optimum solution for a project of this type and size.In specifying the building board for this project it was important to ensure the optimum racking performance to enhance structural strength. Y-Wall conforms to European Norm - BS EN 594:2011 - the certification which proves the system has been rigorously tested and offers excellent racking performance, structural strength and stability.Specifying a building board that is fully tested to BS EN 1062-1 allows for adequate moisture resistance and durability. Y-Wall fully complies with this standard which ensures the building boards will have a life equal to that of the building. Selecting a building board with good external performance and durability is important, particularly through the build phase, as the product may be left exposed for several months prior to a secondary facade being installed over the top of the system. In order to generate speed and ease of construction, Y-Wall was supplied pre-cut to specified panel sizes. The fabrication work was undertaken by Benx Façades at its dedicated facility, to ensure a seamless process.

Sigmat delivered an all-encompassing offsite MMC solution including; 4 levels of hot rolled steel transfer structure with Sigmat's own SFS infill, 5 levels of Sigmat light gauge steel framing with 180mm concrete slabs over SigDeck, roofing, lift / stair cores and stair cases. Alongside additional architectural features such as vertical aluminium brise soleil which helps to manage heat and light, the heart of the scheme also includes a bespoke hot rolled glazed link bridge offering seamless access from the hotel to nearby Sandy Park stadium. The new Courtyard by Marriott Hotel is the largest commercial hotel in the region with 250 bedrooms, ground floor leisure facilities and a spectacular roof top cocktail bar.

The purpose: Energy savings of £¼million over 20 years at just two of its sites are predicted to be achieved by London Fire Brigade through effective roof refurbishment using our Roofing Solutions. The brigade identified that the roofs at Erith and East Ham Fire Stations were in need of refurbishment. Numerous intermediate repairs had already been undertaken. An efficient solution was needed to help London Fire Brigade optimise best value in its asset management and reduce its requirement for planned- or unplanned- maintenance.London Fire Brigade therefore turned to Currie & Brown construction management consultants to oversee the design and execution of the refurbishment projects under a contract management framework agreement in place between the two organisations. We was called in to assess the roofs and advise on a course of action. Data driven roof condition reports from surveys were taken across the two premises. We highlighted that the roofs were beyond economical repair and needed new waterproofing and insulation- a U value of 5.00W/m2K was discovered in one roof area, against the Regulatory threshold of 0.35W/m2K and best practice 0.18W/m2K. Our solution: We advised that in the main, overlaying of the existing roof covering with CP-20 Paracoat Cold Polyurea Liquid System (warm roof) application was the most-efficient and cost-effective solution.The over-laying using the CP-20 system satisfies London Fire Brigade’s policy of preference for flame-free, with no roof replacement needed this minimised waste to landfill.Our Approved Contractor CWG Group won the contracts to undertake the upgrading, working to Langley’s detailed individual specifications for each site.At East Ham Fire Station, four main roof areas plus a separate ancillary building were addressed.LangGuard free-standing safety rail was installed around the perimeter of roofs 1 and 4.The final touch for the field roof area was provided with Paracoat Fast SF slip-inhibiting finish to agreed walkway areas.At Erith Fire Station, the refurbishment involved upgrading two roof areas including a rooftop tank room and adjoining canopy of corrugated PVC over the Station building, and a separate stores roof.

Dacatie's TF Multicloser and SF Multicloser profiles were used in the Phoenix Wharf development of 4 bedroom homes.Phoenix Wharf is located within the Sandwell and Swan Village area of West Bromwich, less than six miles northwest of Birmingham.

“How good is Knauf Insulation’s specification and technical support? Let’s put it this way, I’ve used Rocksilk® RainScreen Slab for every façade project since.”- Nikesh Patel, Façade Design Manager at A2O Cladding The Weald of Kent Grammar Annexe extension is a new three-storey satellite facility for Tunbridge Wells Grammar School for Boys in Sevenoaks. It comprises state-of-the-art classrooms for a cohort of 90 boys. A2O Cladding were appointed by Willmott Dixon to deliver the technical design and installation of the façade, which is finished with a white and grey silicon render set against a red Corium brickslip façade. One of their first tasks was to finalise the insulation specification based on three key requirements: thermal performance, non-combustibility and sustainability. Meeting the thermal performance challenge The first factor, the thermal performance of the rainscreen façade system, initially proved more difficult than expected. Nikesh Patel, Façade Design Manager at A2O Cladding explained: “U-values provided by the architect for a rainscreen façade system are a bit belt and braces because they’re based on assumptions. So, once we’ve confirmed the sub-structure, we redo them to ensure they’re an accurate representation of the building’s thermal performance.”   “The problem is the manufacturer we were working with couldn’t deliver the U-value of 0.18 W/m2K because they didn’t have the right software.” For most applications, the simplified methodology used for calculating U-values is sufficient. But it is not recommended for rainscreen façade systems, because it does not take into account the complex interaction between the Steel Frame System (SFS) and the insulation. Instead, a blanket correction factor is applied, which can lead to the over-specification of insulation – as it had in this case. To prevent this, 3D U-value calculations should be used. They thermally model the build-up based on the complex interaction between the insulation and the rails and brackets. This ensures greater accuracy giving the specifier a true picture of how the build-up will perform after construction, so it matches its design. But most manufacturers don’t have the capability to undertake these complex calculations in-house, so outsource the service to a third party at a cost to the contractor. Before they went down this route, A2O Cladding asked project architect Bond Bryan for advice, who suggested they contact Knauf Insulation.  “We’d not used Knauf Insulation before so didn’t know the standard of their technical support. The biggest tick in the box was they do free 3D U-value calculations – it really helped to keep the project on track.”  Using these calculations, the Knauf Insulation Technical Support Team recommended Rocksilk® RainScreen Slab for the façade insulation. The product has a thermal conductivity of 0.034 W/mK and crucially, a depth of just 150mm would meet the required U-value.  They also recommended 150mm of Rocksilk® EWI Slab with a thermal conductivity of 0.036 W/mK to insulate the rendered external walls. A2O Cladding also decided to use Knauf Insulation’s OmniFit® Slab 35 to insulate the junctions at roof level to ensure continuity of insulation. Fire safety at every height All three products have the best possible Euroclass A1 reaction to fire classification, so will not contribute to the development or spread of fire, should it occur. This meant they met the second specification factor, non-combustibility.  “The Annexe extension is under 18m tall but that would never influence our choice of insulation material. The A2O ethos is that we don’t touch combustible stuff when there are suitable non-combustible solutions available. I mean why would you introduce that risk? Using Mineral Wool insulation gives us, and the school peace of mind.”  Patel goes on to explain that Willmott Dixon has a reputation for quality and will only authorise the use of tested and certified systems. “As the façade contractor, it’s our job to ensure the quality of the supply chain. The fact that Rocksilk® RainScreen Slab is BBA certified for use in high rise buildings and for so many different build-ups meant it met the rigorous standards demanded for the project.” A focus on sustainability But choosing suppliers isn’t just about performance and fire safety. The third factor in the specification process was sustainability.  “As we finalise the technical design, we need to provide Willmott Dixon with a Technical Submittal for every product, and this includes details of its green credentials. It was another example of how Knauf Insulation makes things simple for contractors. They have EPDs for every product and all the relevant ISO standards, so our insulation specification sailed through.” As well as producing products that improve the thermal efficiency of buildings, Knauf Insulation has been taking steps to reduce the carbon footprint of its products. One example of this is its unique bio-based binder, ECOSE® Technology, which contains no added formaldehyde or phenol. ECOSE® Technology is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly. From technical support to performance and sustainability, Knauf Insulation scored top marks in all categories – which meant that A2O Cladding didn’t need to compromise on any of their specification requirements or criteria. 

When completed, A3 New Bailey in Manchester will be one of Europe’s greenest buildings. Not only has it been designed to achieve the toughest sustainability ratings, it will also feature Europe’s largest living wall. But as with any innovative project, it presented some major challenges when it came to the specification of the rainscreen façade system. Meeting the target U-value Lester Cladding NW Ltd were responsible for the design and build of the façade. A rock mineral wool product with a thermal conductivity of 0.035 W/mK had been specified. But when conducting the calculations, they instantly ran into a problem. An insulation depth of 240mm was required to achieve the U-value of 0.15W/m2K.  Jamie Simm, Operations Director at Lester Cladding NW Ltd explained: “There was a strict external and internal boundary, so we needed to keep the façade wall build-up within those measurements. But the amount of insulation needed to meet the target U-value increased the depth of the wall, pushing it over the boundary line.” When looking for an alternative solution, the company approached Knauf Insulation’s Project Specification Team to discuss the brief. As well as meeting the thermal performance requirement, the insulation needed to comply with building regulations that ban the use of combustible materials in the external walls of certain buildings over 18m tall. It also needed to help reduce noise and meet the project’s sustainability targets.  After running 3D U-value calculations, Knauf Insulation’s Technical Support Team recommended 170mm Rocksilk® RainScreen Slab for the ventilated façade, a rock mineral wool insulation which has a thermal conductivity of 0.034 W/mK. For the Steel Frame System (SFS), they recommended 150mm OmniFit® Slab 35, a glass mineral wool insulation with a thermal conductivity of 0.035 W/mK.  This combination reduced the thickness of the wall build-up by a significant 70mm, ensuring the U-value could be met within the required parameter for the wall build-up. Simms said: “Not only did Rocksilk® RainScreen Slab offer superior U-value performance for a slimmer profile, it reduced costs across the whole build. As well as reducing the quantity of insulation required, we could use smaller helping hand brackets and thinner fire barriers for example. It was the product that steered the job through.” In addition to achieving the required thermal performance, both products are non-combustible with a Euroclass A1 reaction to fire classification. This means they will not add to the development or spread of fire, so comply with the building regulations. Rocksilk® RainScreen Slab is also British Board of Agrément (BBA) certified for use in buildings of any height and for the broadest range of thicknesses and build-ups of any rainscreen solution on the market. Mineral wool also has an open fibre matrix, which means it has sound absorbent properties. The insulation will help to reduce noise from the busy city centre location and from disturbing residents. Project complexity The choice of insulation was not the only challenge for the build. There is no template for supporting Europe’s biggest living wall. So, Lester Cladding NW Ltd needed to draw on their own extensive knowledge and expertise, as well as that of the whole supply chain to create a bespoke solution from the ground up.   One problem with this approach, was that every potential solution impacted another aspect of the façade build-up. To overcome this, Lester Cladding NW Ltd took the unusual step of arranging a meeting between representatives from eight different design and manufacturing partners. Together they discussed the whole system ‘screw by screw’.  “Getting everyone sitting around the table meant that all our manufacturing and design partners were completely engaged. They understood what we were trying to achieve, and all worked together to find the best solution.” There was one particular factor that could affect the insulation – water. While a living wall utilises planting schemes that thrive in drier conditions, a 4,000m2 living façade still requires a lot of watering – something that could introduce lots of extra moisture into the system. Knauf Insulation’s Rocksilk® RainScreen Slab has a water-repellent additive that promotes water run-off and ensures the slab will maintain its integrity. A traditional façade system prevents the insulation from getting saturated by rainwater, while the ventilation reduces the build-up of condensation and allows the insulation to dry out if it does get wet.  However, the water-repellent additive does not make the insulation waterproof, so it needed protection from the constant flow of water from the irrigation system. As a result, an additional breather membrane was installed to prevent moisture from penetrating the façade system and affecting the insulation. Sustainability A3 New Bailey has been designed to UKGBC’s Net Zero Carbon Framework and WELL Building Standard principles, as well as to achieve BREEAM Outstanding and Wired Score Platinum ratings. This meant the sustainability of the construction materials themselves was also important.  Here Knauf Insulation’s products ticked all the boxes too. Its glass and rock mineral wool insulation are made from materials that come from either naturally abundant sources or are recycled. For example, its glass mineral wool is made with upto 80% recycled glass from locally collected and processed household bottles and jars. Glass mineral wool has the lowest levels of embodied carbon of any mainstream insulation material. So, combining the use of both Knauf Insulation glass and rock mineral wool meant that the insulation solution for A3 New Bailey had less embodied carbon than a traditional all-rock insulation solution. Both products are also manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. ECOSE® Technology is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than a traditional binder. They also generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. This contributes to the health of both installers and residents. Its entire glass mineral wool product range is also Declare Red List Free, which means that it does not contain any harmful chemicals on the ‘Red List’.  Thanks to Knauf Insulation’s advice, technical support and high-performance insulation solutions, Lester Cladding NW Ltd was able to deliver the rainscreen façade for A3 New Bailey – and with it, Europe’s largest living wall.

ChallengeTargeted with achieving a minimum BREEAM rating of Excellent and with only a short window of time to complete the project, Associated Architects, who designed the building, needed insulation products that would meet strict thermal and environmental requirements – as well as a manufacturer that could offer quick turnaround times and a high level of technical support.SolutionWith the help of Knauf Insulation specification manager, Marc Lawson, a through wall solution using 5,000m² of Knauf Insulation’s 100mm Rocksilk® RainScreen Slab – a rock mineral wool slab containing a water repellent additive, specifically designed for rainscreen cladding systems was used. It is quick and easy to install and is simple to cut and fit around brackets. The slabs knit together with no need to tape the joints – ensuring maximum acoustic and thermal performance, with no air gaps. Knauf Insulation’s Rocksilk® RainScreen Slab is also non-combustible and has the highest Euroclass A1 reaction to fire classification, as well as excellent sound absorption performance.To further enhance the thermal properties of the element, 10,500m² of Knauf Insulation’s Rocksilk® Flexible Slab 100mm, was installed in two layers within the SFS system. Designed to friction fit between metal studs, rafters and joists, Rocksilk® Flexible Slab is a multi-purpose rock mineral wool insulation slab, which provides excellent thermal and acoustic performance.Chris Kinman, Senior Design Manager at Willmott Dixon commented; “Knauf Insulation’s products are easy to handle and cut which makes them very easy to use on site. The first phase of the project has gone well, and the architect has adopted a similar approach to Phase 2 - which is testament to the excellent performance so far. Overall, we have been very impressed by the help and support we have received from Knauf Insulation on the project, and we have since recommended them to other colleagues."Rocksilk® RainScreen Slab and Rocksilk® Flexible Slab rock mineral wool products are made with ECOSE® Technology, a formaldehyde-free binder derived from rapidly renewable materials, instead of traditional petro-based chemicals used in other insulation. Additionally, ECOSE® Technology is up to 70% less energy intensive than traditional binders.