THE SUSTAINABILITY CASE FOR PVC-U

With pressure on the construction industry to utilise more sustainable building methods and product choices, specifying a PVC-U solution is increasingly being seen as a way to further drive the green agenda.

Eurocell is supporting sustainability options for housebuilding and commercial projects through its market-leading PVC-U recycling and manufacturing processes that are substantially reducing the amount of plastic waste heading for landfill and helping to tackle the problem of carbon reduction. The company offers an extensive range of high performing PVC-U window and door solutions that not only look good, but also help organisations satisfy their sustainability ambitions.

Momentum is building across all parts of society as consumers, businesses and politicians look for answers to the escalating climate crisis.  Consumers want to see action and as a result, companies are looking closely at how their activities and processes are impacting the world. In the UK, the government has set out bold carbon reduction targets as part of its net zero strategy.  One key area is the nation’s housing stock and policy makers looking to deliver a difference have the construction industry firmly in its sights.

The new Part L Building Regulation and the Future Homes Standard – which is seeking a 75% reduction in CO2, compared to current levels, in new builds by the middle of the decade – is tasking architects, specifiers, developers, and construction firms with uncovering the right construction methods and building fabric product choices to support a more sustainable, energy efficient and less wasteful future.

PVC-U is already playing its part in helping the construction sector meet important environmental and regulatory obligations.  Set against other potential product choices such as aluminium or timber composite, PVC-U offers long-term durability and high performance, attractive aesthetics to support design visions, cost effective value and, through Eurocell’s vision and industry leading recycling processes, a truly sustainable answer.

Recycling with a purpose
Eurocell has been committed to supporting the aims and ambitions of recycling for over twenty years.  Recognising a corporate need to do what is required to minimise plastic waste and where possible reuse materials across large scale manufacturing processes, the company has moved from externally purchasing recycled plastic to the establishment of its own nationwide waste recycling system, used to supply Eurocell’s manufacturing operation with recycled plastic raw material.

Such has been the success of Eurocell Recycle, the result of its processes now see it account for around 80 – 90% of all the material Eurocell’s manufacturing business requires to generate an extensive range of brand-new extruded plastic products.  As part of this, Eurocell now recycles around 3.5 million discarded frames per annum, with such post-consumer waste combined with virgin PVC-U to produce extruded material used for new frames and other products such as cavity closers.

Without this service, a high proportion of the PVC-U waste generated by large manufactures, fabricators and installers would simply end up in landfill and contribute further to the waste disposal challenge the UK continually faces.

‘Closed loop’
The ‘closed loop’ system is a six-stage recycling process.  Starting with a national collection service operated by Eurocell Recycle.  Old and discarded PVC-U windows, door frames and other PVC-U offcuts are collated by Eurocell Recycle’s fleet from company locations and waste management centres across the UK.  On arrival at one of the recycling processing plants, the material undergoes an extensive sorting and separation process which divides metals, white polymer, and coloured materials, as well as capturing material which is ultimately non-recyclable.
After a transformative process which creates a powder or pellet form that matches virgin PVC-U material, the recycled plastic is used by Eurocell to manufacture its extensive range of extruded PVC-U products.   The fabrication of new products such as window and door profiles then follow, leading to the installation of many new products in homes and commercial buildings ultimately fashioned from thousands of old windows and door frames that have reached the end of their working life.

And the recycling process promises much for the future.  New PVC-U windows using recycled polymer can last up to 35 years and the material can be further recycled up to ten times delivering ongoing sustainability benefit for generations to come.

PVC-U performance
When set against alternative product choices for windows and doors, PVC-U is proven to deliver an enhanced thermal performance. Combined with effective glazing solutions, buildings can be better insulated and use less energy with PVC-U’s ability to offer a lower U-value for lower cost.   For large scale housebuilding developments or commercial projects, the option to achieve excellent thermal performance results through a cost-efficient product choice without compromise, is a reason why PVC-U and popular Eurocell solutions such as MODUS and LOGIK windows that contain high levels of recycled content, are becoming the sustainable product choice for many.

Proven benefit
With carbon saving the true test of strategic sustainability plans, Eurocell is committed to working with the sector to deliver tangible results and undoubted benefit.
By transforming waste PVC-U material destined for landfill into a high performing, thermally efficient, aesthetically pleasing, and cost-effective PVC-U window and door solutions, Eurocell is the proven sustainability choice for the construction sector at a time when it is needed more than ever.
For more information about Eurocell’s extensive range of PVC-U solutions and its commitment to a sustainable future, please visit the website.

www.eurocell.co.uk

/0 Comments/by

Bricks? A modern method of construction?

By James Mead, projects director at Saint-Gobain Weber.

If you ask most people what their house is made of, the chances are they’ll tell you it’s made of bricks. In fact, around 70% of the UK’s new homes are built with a brick façade proving that this traditional style has retained its popularity since 7000BC, when the people of Jericho made the first bricks from mud and dried them out in the sun for hardening.

Today’s bricks are kiln dried and are much heavier than a mud brick – so the costs in terms of freight, emissions, weight, space, and storage are significant. The other pressing issue with bricks is bricklayers: They’re in very short supply and laying bricks is such a skilled craft, it takes a long time to gain the experience to do a decent job.

With a call for bricklayers to be added along with lorry drivers to the Government’s Shortage Occupation List, and existing bricklayers charging a premium, we need to find a way to construct buildings that are traditional in style but modern in construction.

Those building homes in the social housing sector also have another concern: the Government’s Affordable Homes Plan, delivered through Homes England, specifies that the projects it funds must contain a minimum of 25% MMC. It also sets a measure against which MMC projects will be assessed – the Pre-Manufactured Value (PMV). This is the financial proportion of a project’s gross construction cost through pre-manufacturing. To pass Homes England’s MMC test you need to have at least a 55% PMV.

 

Calculating PMV

To calculate a building’s PMV, each element that is delivered through an MMC process or product will add to the overall percentage. There are seven categories awarding percentage points. For example, in category one is ‘Pre-manufactured 3D primary structural systems’ like a volumetric modular housing unit. This will give you the highest percentage. In category three ‘Pre-manufacturing components (non-systemised primary structure) components’ – such as beams, staircases or trusses would also boost your percentage.

Category six deals with building products and systems that reduce labour on site and improve productivity. One area where it’s easy to specify a PMV improving element is using a modern alternative to traditional brickwork.

Encouraging MMC in the private sector

Of course, it’s not just in the social housing sector where the principles of MMC and increasing the use of off-site manufacturing are important. Private housing developers must also adopt MMC to play their part in the fight against climate change.
The construction industry is responsible for 38% of CO2 emissions, so any products that can reduce both wastage and HGV deliveries to sites are going to make a huge impact on this figure. MMC also addresses labour shortages by using products made in factories without the need for specialist skills, and off-site manufacturing reduces construction waste which accounts for 59% of waste produced in the UK.

Traditional in appearance, modern in application

Saint-Gobain Weber has developed weberwall brick to help bridge the gap between traditional and modern methods of construction. We have developed a façade alternative that gives the appearance of brick but can be fitted without the need for specialist labour on site. Once applied, it feels and looks just like the real thing.

Ideal for developments or refurbishment projects where planning permission requires a brick façade, weberwall brick is lightweight and quick to apply taking around 17 minutes to install 2sq m. Cladding the equivalent area in brick slips takes just under an hour and when the whole build is taken into account it can be up to 50% faster than using a traditional brick slip
The lightweight brick slip system can be applied directly to the substrate with a specially formulated render. It is then pointed in the same way as a standard brick so, once installed, looks no different to traditional masonry.

It can be programmed into CAD systems to minimise waste and is designed for use with the most commonly used MMC systems so ideal for steel, wooden frame and panellised systems. weberwall brick forms part of BBA approved systems and is suitable for new build or refurbishment projects where it can give a building a completely new look.

If developers are going to truly grasp MMC to combat the housing crisis through centralised funding, they are going to need to adopt creative and innovative solutions to increase their project’s PMV whilst conquering the multiple difficulties posed by today’s construction industry, weberwall brick is certainly up to the challenge.

www.uk.weber

/0 Comments/by

Modular teaching block for new High School

TG Escapes Eco-Buildings provide modular teaching block for new High School

The High School Leckhampton, is a brand new co-educational comprehensive school that will serve south Cheltenham. It is being built to cater for an expansion in pupil numbers at secondary level in the area. The school has been commissioned by Gloucestershire County Council but is being “sponsored” and developed by Balcarras.

TG Escapes Eco-Buildings were appointed to provide a stand-alone eco-building to accommodate the school’s intake in time for September 2021. The modular timber frame solution provides a fast build process with minimal disruption, and delivers a bespoke permanent building designed to last 60 years or more.

Ian Davidson, Assistant Head and Jeff Arris, Network Manager at Balcarras School explain the background and their experience of the project.

Why was the building needed?
IAN: Balcarras School were awarded the contract for an entirely new school, to teach 900 11-16 year olds, which was due to open in time for the start of the school year in September 2021. The initial phase of opening was for 120 Year 7 students with subsequent yearly intakes increasing until the school will be operating at full capacity with 5 year groups of around 180 pupils each.
Towards the end of 2020 it became apparent that the new school building would not be completed in time to welcome the initial intake of students. The existing school was operating at maximum occupancy and there was simply no space available to accommodate the new students.
The decision was taken to build a modular suite of 4 classrooms on the existing school site, each designed for around 30 Y7 pupils, to be used for classroom-based subjects (maths, English and social sciences). Science, art, DT and PE lessons will take place within the main school facilities.

What was the process for selecting the bulding provider?
JEFF: The year previously, the existing school had engaged with 3 contractors to provide a modular building to extend its IT facilities. TG Escapes won the tender process but it was ultimately decided to not proceed with the project.
However, TG Escapes had sufficiently impressed that they were selected as one of the 3 contractors invited to tender for the new project and again were the preferred choice. The governors were naturally concerned about timely delivery and potential overspend and engaged Evans Jones consultants to oversee the build, which commenced in January 2021.

How did you find the process?
IAN: I thought it was quite brilliant. My biggest concern was that the building would be completed on time, but I have never seen a building go up so quickly. Throughout the build the project manager was very approachable and easy to deal with. Any problems were immediately solved, avoiding any interruptions to the day to day running of the existing school site. All potentially disruptive operations such as crane and material deliveries were organised to fit the school timetable.

JEFF: The site was well managed and the project manager was fully engaged with the school throughout the build, securing agreement before each phase. Regular meetings between the school management team and the project manager were handled thoroughly and efficiently and the building was completed weeks ahead of schedule in May.

What do you think about the building’s quality now it is in use?
JEFF: It is good and functionally it is working well, particularly pupil flow. We are expecting the outside decking areas to be a very useful space.
Ian Whilst there have been a few snagging issues these are being well dealt with promptly. The finished look of the building is really good and reminds me of a “Grand Designs” project. The parents love it and the feedback from staff and students is also very positive. It feels both spacious and luxurious.

How important were the eco credentials?
IAN: Very important. Zero carbon and environmental issues have become a big consideration across the education sector.
Jeff The speed of construction versus a traditional build process was also of high importance. I was impressed by the lack of waste, helped by the donation of spare materials to the existing school.

For more information about TG Escapes Modular Timber Frame Buildings call 0800 917 7726 or email info@tgescapes.co.uk.

CLICK HERE To see a timelapse of the build in progress

www.tgescapes.co.uk

/0 Comments/by

Bringing Modular Benefits to Heat Networks

Heat Networks are an increasingly popular solution for urban developments, promising efficient heat for occupants, reduced maintenance, and a much simpler transition to low carbon heat in the future. One challenge these projects pose is that domestic hot water pipework must be maintained at a constant warm temperature so that it is always available for use. As a result, gaps in the insulation around services, or use of insufficient pipe insulation, can raise heating costs and increase overheating risk in the summer months.

To address this, developers are increasingly looking to offsite approaches, allowing services to be fabricated in modules before being installed on site. In addition to accelerating onsite processes and ensuring consistent quality, this can also allow for improved access during fabrication and pre-testing prior to installation. To further support project teams, CIBSE has released CP1 Heat networks: Code of Practice for the UK (2020), setting over 500 minimum requirements for these systems.

CP1 and the growth of heat networks
Heat networks distribute heat from an energy centre/s to either an individual building (communal heating) or multiple buildings (district heating). One of the key advantages with this technology is that it is ‘fuel agnostic,’ meaning a whole range of sources can be used for the energy centre. It is therefore possible to install a network which initially uses a gas-powered energy centre, then transition to a low-carbon alternative as they become available.
Whilst this technology has been used globally for decades, it is still relatively new here in the UK and CP1 (2020) has been designed to assist effective deployment. The insulation of secondary pipework (the pipework that runs inside the building) provides a good example of how it works— providing simple minimum requirements whilst encouraging specifiers to look to enhanced specifications.

Pipework Insulation
Objective 3.9.7 of CP1 provides minimum insulation thicknesses for different secondary pipe diameters. In most cases, a 50 mm thickness of either phenolic or mineral fibre pipe insulation is required.
The use of minimum insulation thicknesses, rather than heat loss parameters, is designed to provide clarity but also has limitations. In particular, phenolic insulation is notably more effective at preventing heat loss at a given thickness than mineral fibre. This means that heat losses may increase by between 30% and 39% when the minimum mineral fibre specification is used instead of the phenolic equivalent.
To address this, CP1 also requires project teams to carry out pipework heat loss calculations at the Feasibility Stage (Stage 2) and to create detailed pipework insulation specifications based on project specific parameters at the Design Stage (Stage 3). The benefits of enhanced pipe insulation specifications should be considered during this process, both to reduce energy demand, and minimise overheating risk.
Additionally, CP1 also highlights the importance of ensuring a continuous layer of insulation across all areas of the services and the use of “rigid low conductivity inserts” to prevent heat transfer through pipe support.

East Village
Alternative Heat recently put CP1 principals into action when developing the design, fabrication and delivery of shell and core service packages as part of the heat network for N06 East Village in London. The project features 524 build-to-rent apartments at the former London 2012 Athletes’ Village with the project team including M&E consultants, chapmanbdsp, M&E contractors, Borough ES, and thermal insulation contractors, Commercial Insulation Services.

To ensure efficient delivery, the project was completed to Level 2 BIM and Alternative Heat supplied services in a number of modules, including skid mounted plantrooms, mechanical utility cupboards, laterals and risers which could be simply lifted and installed. Kingspan Kooltherm Pipe Insulation and Insulated Pipe Support Inserts were specified for a range of Low Temperature Hot Water (LTHW) and Boosted Cold Water System (BCWS) pipework within the modules to meet key performance criteria. As Damien McMullan from Alternative Heat explained:
“The development uses a district heating system, so it was essential to keep heat losses from the pipework to a minimum. For this reason, the specification from chapmanbdsp required the pipework to be highly insulated and compliant with the CIBSE CP1 Heat Networks guidance. The combination of Kingspan Kooltherm Pipe Insulation and Insulated Pipe Support Inserts allowed us to easily meet these requirements across the different pipe diameters.”

Complete Solution
Modular building services solutions offer clear advantages for heat networks. By ensuring these meet the requirements of CP1, and looking at how you can go beyond these, it should be possible to maximise the long-term cost, emissions and energy savings on these projects.

www.kingspantechnicalinsulation.co.uk

/0 Comments/by

Adding the finishing touches to MMC projects

Top performing FR panels add the finishing touches to MMC projects

Panels are the perfect addition to a modern build. A consistent, repeatable product that is quick to install and available in standard sizes across a range of decorative finishes, they offer the perfect finishing touch, whatever the design.

One consideration high up on the agenda for specifiers when designing public buildings, such as schools, hotels and medical centres, is fire protection.  Reducing and managing the risk of fire is an essential consideration and there are a range of panels available on the market that can help.

Here, Lathams explore three of its top performing Fire Resistant (FR) panels. Structural product SMARTPLY FR B is a good place to start. Used for floors and walls, it is a moisture resistant, flame retardant Euroclass B panel (B-s2, d0).  What makes this product unique is the way in which it is produced. Individual flakes of wood are treated with a water-based FR solution before the panel is manufactured. This means that the fire protection is maintained throughout the panel, so it can be cut or machined without losing any of the fire performance. The boards are produced using ContiRoll® technology, making this a highly flexible product because it can be rolled out to any size. Essentially, the OSB panel goes under rollers on a continuous conveyor and is only cut once the desired length has been reached. With sizes of up to 2.8 x 7.5m achievable, they are ideal for the MMC sector.

Garnica Fireshield is also rated Euroclass B (B-s1-d0). It is a modified plywood that undergoes an innovative ply-to-ply process which results in strong flame retardant properties. Like the SMARTPLY FR B product mentioned above, this process means that it can be cut or adapted without negatively affecting the fire performance.  It is a lightweight product making it perfect for the offsite market; whether installed within the factory or sent directly to site, it is easy to transport and handle. Sourced from sustainably managed European poplar forests, Garnica Fireshield is often used for ceilings, walls, doors, frames and partitions. Suitable for a range of sectors, its certifications make it one of the best performing wood products, offering low carbonisation, low smoke emission and an absence of flaming particles in the event of a fire.

For those looking for something with more decorative options, High Density Fibreboard (HDF) Valchromat FR provides fire resistance across a range of 11 colours.

The boards are ‘through coloured’, with the dye embedded throughout the panel. This means that it can be easily machined, offering clean cuts and a uniform finish with a consistent colour. It is perfect for locations that need a bit more colour but do not want to compromise on performance.

The Euroclass B-s2,d0 Flame Retardant version is perfect for branded environments that perfectly blend in, and is heavily utilised in commercial fit outs, retail and hospitality environments, exhibitions, museums, and schools.

To find out more about these products or the wider Lathams range, PLEASE VISIT the below website or email info@lathams.co.uk

/0 Comments/by

SIKA HELPS MAXIMISE OFFSITE EFFICIENCIES

SIKA’S MODERN METHODS OF CONSTRUCTION DIVISION HELPS MAXIMISE OFFSITE EFFICIENCIES

The advantages of offsite construction to encourage greater efficiency, consistent quality, less waste and higher productivity will go some way to addressing the high demand for new buildings. As an alternative to traditional building techniques, offsite solutions are not new to the construction industry but are proving to be a cost efficient and sustainable alternative to traditional methods of construction and can help address skilled labour shortages. With its long track record of success as a complete system and problem solution provider, Sika’s modern methods of construction (MMC) division works with offsite manufacturing and assembly companies to look at how Sika products can be used as part of the process in this fast-growing sector.

Sika’s decision to create this team of experts in 2019 came at a time when offsite manufacturing was growing in popularity, as a result of its multiple benefits including improved quality control, reduced waste and speed of construction. Its extended team of offsite manufacturing specialists across Europe cover a breadth of skill and expertise. As a business, Sika has many products that can be used in offsite construction, both within production assembly lines and/or application upon delivery to site, for a variety of purposes.
Sika offers the industry’s widest product ranges for sealing and bonding, roofing, building finishing, passive fire protection, damping and reinforcing, concrete, flooring, waterproofing and wall finishes for interior and exterior applications, and bathroom pod waterproofing and tiling systems.
Sika has an extensive R&D capability and global reach. This means the company has a proven track record of working across international markets, many of which are on the pulse of offsite manufacturing’s innovations. Sika’s MMC division is utilising global experience to guide offsite manufacturing companies towards unlocking new potentials. The division offers a customised approach for modular manufacturers, especially where construction solutions need an industrial approach.

Offsite school project
One project where Sika products have played an important part in offsite construction is for an award-winning school project in Birmingham. Sika provided a technically advanced, high-performance, hybrid roofing membrane for the newly-constructed King Edward VI Northfield School for Girls in Birmingham, which was built using innovative offsite construction techniques.
To meet performance and programme goals for the building’s construction, a hybrid design was devised by offsite construction and modular specialists, Innovaré, which included integrated BBA-Certified i-SIP panels, hollow core concrete plank floors, and a lightweight timber cassette roofing system. This hybrid method of construction, which meant most of the new school structure was manufactured offsite, offered a radically quicker speed of build, reducing preliminary and overall costs. It also ensured the building’s performance and programme goals were met.
Sika’s 4mm elastomeric and plastomeric bituminous hybrid membrane, SikaBit Pro 940®, provided the watertight finish for the new building’s energy-efficient roofing system, which integrates timber cassettes with i-joists.
SIkaBit Pro 940® combines the advantages of APAO and SBS-modified bitumen, allowing two different compounds to work together. The upper layer comprises APA-modified bitumen, offering excellent heat resistance and durability. The under layer is SBS-modified bitumen, providing increased elongation, improving flexibility and excellent resistance to thermo-oxidative aging which will last longer than traditional membranes and reduce ongoing maintenance. SikaBit® has been developed to comply with the NFRC’s Safe2Torch Guidance to help specifiers prioritise safety at the design stage of roofing projects.
The specification of SikaBit Pro 940® as part of the school’s energy-efficient roofing system contributed to the building’s fabric achieving required levels of thermal, airtightness, acoustic and maintenance performance. In terms of the roof’s construction, Innovaré manufactured large-format structural timber roof cassettes, ensuring that the structural members and deck went into place quickly.

 

LW Roofing, one of Sika’s Certified Roofing Contractors, was responsible for the design and installation of the roofing system. In addition, RLW Roofing completed façade works, using Sika Parex Historic Mortar KL.
“We are proud that in collaboration with RLW Roofing, our products and expertise were used to successful effect in the delivery of this wonderful school, RLW’s skill and expertise were instrumental in delivering a technically robust solution” Simon Griffiths Head of Sales, Offsite Construction at Sika, said. “The hybrid method of construction implemented by Innovaré for this project aligns perfectly with Sika’s promotion of sustainable development within the construction industry.”

Offsite alliance
As part of its commitment to offsite manufacturing across the nation, Sika has recently joined Offsite Alliance, a membership organisation that increases the uptake and delivery of offsite technologies in the residential sector. Through a combination of action and collaboration, Sika will work with fellow like-minded organisations to promote best practice, share innovation and work together to create the high quality, sustainable homes of the future.
With extensive technical expertise and solid practical experience on every continent, in many climates and environments, Sika is a highly qualified, reliable partner for all manner of manufacturing and construction needs.

www.sika.com

 

 

/0 Comments/by
,

Modular homes – are we storing up problems for the future?

by Jim Edwards, Commercial Director of Global Warranties

 

The market for modular and prefabricated buildings continues to boom, but are we storing up problems for the future that may ultimately cost millions of pounds in repairs and heartache for home owners? According to Global, the country’s fastest growing supplier of insurance backed latent defect warranties, it is a real possibility.

Manufacturers from every part of the globe are now producing and developing more components offsite than ever before with industry estimates suggesting that some 15,000 new modular homes are being built every year in the UK alone – a figure that is rising rapidly.

Every new home requires a latent defects warranty to cover anything unforeseen that might happen between year two and year three. During the first 24 months the builder is responsible for correcting any issues.

It is a system that has traditionally worked well, with more conventional homes seeking a latent defects warranty, being inspected at every stage of the build process. Companies such as Global have a multi stage inspection guide from the moment footings are dug and concrete poured, right up to final delivery, to ensure that each home is fit for purpose.

“The problem is,” said Jim Edwards, commercial Director for Global Home Warranties, “how do you inspect modular components for latent defects? This would require sending our surveyors to every factory currently producing such systems, as far away as China in some cases.”

“This means that while we can inspect the way they are installed, we equally have to accept that offsite components are fit for purpose and have reached the highest possible standard. In most cases this is very much the case, but there is no way of knowing 100% and this is where the real problem lies – without independent inspection at the factories then it is not possible to determine whether we will have to address latent defects issues in the future.”

The market for modular buildings is expected to grow in excess of 6% year on year and there are estimates that the majority of contractors architects and engineers are now designing with or using modules built offsite.

The move to offsite construction has been driven by the need to meet Government targets to build up to 300,000 new homes every year which means that modular and prefabricated components are increasingly being used.

Companies in the UK specialising in offsite construction have an enviable track record in terms of quality and mostly produce components which have been ISO certified or meet all current building regulations and standards.

This means, according to Global, that it will more likely to be imported systems that ultimately fail, possibly because overseas manufacturers are not as familiar with or as aware of building practice within the UK and European construction sector, or simply because standards have been set lower to save money.

“As we know, price is very much a factor within all areas of construction and there is likely to be a temptation to import more and more low-cost building systems,” said Jim Edwards. “They may do exactly what it says on the tin but none of us yet know what is likely to happen two, five or even 10 years down the line and now is the time to ask ourselves – should we be more stringent by having independent inspection processes in every factory that produces such materials.”

There is growing evidence and other industry experts agree that we could be storing up problems. Recent reports suggest that the lack of detailed data on the durability of modular homes in the UK could be a considerable barrier for construction professionals concerned about the long-term viability of offsite components.

Financial service providers, including insurers, mortgage lenders and valuers need to have certainty that modular homes are safe and durable if they are to engage with them, which is why we are now seeing Global and other industry experts calling for the development of a digital database that records the design, processes and materials used in the construction of buildings.

Digital technology would make it possible to create a database that would store and track information about the built environment and would record the materials and processes used. It could also track repairs and alterations in larger housing developments and make sure that this information would be available to relevant stakeholders, including insurers and fire services.

“This will never be as good as a personal inspection process,” said Jim Edwards, “but it would certainly provide more confidence and peace of mind for the entire industry and ultimately for the insurance companies that have to back latent defects warranties – and the time to act is now.”

 

GLOBAL WARRANTIES WEBSITE

/0 Comments/by

CURING INNOVATION FOR CONCRETE

INNOVATION FROM ARAMCO – One of the world’s largest integrated energy and chemicals companies, part of the global effort toward building a low carbon economy.

 

 

After water, concrete is the most widely used material on earth. Approximately 4 billion tons were produced in 2019, and that amount is set to rise over the coming years. However, creating the principle ingredient – cement – is also responsible for around 7% of annual global CO2 emissions.

While there is a clear desire to reduce CO2 emissions across the whole concrete industry, our focus has been on the usage rather than the production of cement. We are innovating the way concrete is manufactured to utilize CO2 as part of the curing process.

 

The basic building blocks

In its simplest form, cement is combined with sand, water, and aggregate to produce concrete. When the cement and water are mixed, it causes a chemical reaction called hydration, which starts to set and harden the overall mixture.

This process can be affected by a number of factors, from the outside temperature to the amount of cement in the mixture. What is crucial though, is that the concrete retains the right amount of moisture and is kept at the right temperature over a period of time (normally 28 days) to attain its full strength. If it dries out too quickly, the concrete will be significantly weakened – and that’s where curing comes in.

 

Curing is crucial

The curing process not only increases the strength of the concrete, it also makes it more durable, less permeable to water, and more resistant to cracking, freezing, and thawing.

There are many different curing methods available, from using steam or spraying the surface with a fog mist, through to covering it with moisture-retaining fabric or plastic sheets to prevent moisture loss. We saw the opportunity to innovate a new way of curing concrete using waste CO2.

A win-win scenario

Technologies like mobile carbon capture and carbon capture at industrial plants have proven successful at stopping emissions from reaching the atmosphere. But the question remains, what do you do with all the waste CO2 you’ve captured?Options include sequestering it deep underground, transforming it into new products through technologies such as Converge® , or, as in this case, developing a way to recycle it.Reusing waste CO2 is one of the four “Rs” (alongside reducing, removing, and recycling), contributing to the circular carbon economy. We believe this idea has the power to reduce global emissions while ensuring consistent economic growth. And our carbon curing innovation is a perfect example of this in action.

 

Precast was the way forward

The two most common methods of laying concrete are ready-mix and precast. They can both contain the same ingredients, but are produced in very different ways.

Ready-mix is manufactured in a plant and then transferred in cement mixers to the building sites where it can be poured into place. This can have a significant impact on the surrounding environment through increased dust, noise, and transport emissions.

We decided to focus on precast, which utilizes reusable molds to prepare, cast, and cure the concrete in a controlled environment — all in one location, all off-site. The finished products can then be transported to the construction site to be laid in place.

The use of molds reduces any potential errors, and makes it quicker and more efficient to produce large amounts of identical components, such as wall panels, staircases, pipes, and tunnels, which often sit alongside structural steel frames and concrete produced on site.

As well as being able to control the curing environment, precast concrete has several advantages, including lower labor and transport costs, and is a growing industry, valued at around $116 billion in 2019.

Stronger concrete. Produced faster

Following our successful lab test, we put our technology to work in a local precast concrete plant.

The most important test that our carbon-cured concrete had to pass was measuring its mechanical strength. The industry standard is 35 megapascals (MPa), and if a batch of concrete fails to reach it, it will be rejected completely.

We found that our technology not only exceeded the benchmark – it did it in a quarter of the time. Just 3 days instead of 28.

And what’s more, our concrete was also more durable than traditional concrete, showing lower water permeability and greater chlorine and sulfate resistance, all of which are crucial in construction offshore or in in places with high humidity.

 

Building for the future

Having achieved 20% CO2 uptake in a lab setting, the potential for our technology is huge once it is commercialized.

In fact, if the global precast concrete industry switched to our carbon curing innovation, we could recycle up to 246  million tons of CO2 a year – equivalent to removing emissions from 53 million cars.

Our next goal is to increase the amount of CO2 that can be absorbed into the concrete, as well as further reducing the time it takes to cure it. In addition, there is the opportunity to rethink where the waste CO2 is sourced from.

Imagine if we used the CO2 created by the cement production process itself? Then we would be able to reduce the environmental impact of the industry as a whole, and help it transition to a lower-carbon future.

/0 Comments/by